Guard Industries, Inc.
May 25, 2010
 
Dear O&P Professional,


Guard Industries has DURAFLEX™ plastic that works really well for fabricating a flexible inner socket.  See below for more details and fabrication instructions.
Flexible Inner Socket 
 
DURAFLEX™ 
 
A soft, semi-transparent, pliable thermoplastic that combines comfort, durability & strength. 
 
Flexible Inner Socket 
   
 
 
 
 
 
  • Bends with patient, enhancing comfort at trim lines
  • Does not contain either silicone or latex - nothing to irritate the patient's skin
  • Can be blister formed or draped with a seam (that will not come apart) and the seam can be finished off smooth and flush with the socket
  • Crack and tear resistant
  • Minimal, negligible shrinkage
  • Will not turn yellow over time
  • Is hygenic and non-toxic
  • Will not expand due to lotions & creams
  • For above or below knee or elbow applications
  • Flexible and extremely strong
  • Less skin traction than other flexible materials
  • Excellent bonding properties
  • Does not lose memory after cooling
DURAFLEX™is available in the following thicknesses:
1.5MM (1/16")               5MM (3/16")               9MM (3/8")
3MM (1/8")                   6MM (1/4")               12MM (1/2")
 
 
Instructions for Using DURAFLEX™ 
For Flexible Sockets 
 
 
  1. Pre-heat the oven to 250F when blister forming (using a frame) and 350F when drape forming with a seam.Use plaster/vermiculite mix.  No sealer, ambroid varnish or lacquer should be used.
  2. Place the positive model on the vacuum forming platform.
  3. When the material has dropped 1/2 the widht of the frame, it is ready to be formed.
  4. DO NOT flip the frame over.  Slowly pull the material down the length of the model until the frame seals off at the platen.
  5. Apply vacuum slowly so that any wrinkles or webbing can be worked out before full vacuum is applied.
  6. Leave mold under full vacuum a minimum of twice the amount of time it took to heat the plastic.
Plaster Mold Considerations
  1. Use plaster/vermiculite mix.  No sealer, ambroid varnish or lacquer should be used.
  2. Make sure that the positive model is smooth and free of voids.
  3. For a model that is over 14" in length, heating the cast is recommended in order to lengthen the working time of the material.
  4. DO NOT use stockinette or hose as wicking.  The DURAFLEX™ will bond these materials.
  5. Using slightly wet, room temperature or warmer mold works best.  Cold casts should be warmed to at least room temperature. 
Thermoplastic Outer Frame Information
  1. DO NOTpull polypropylene, co-polymer or any other material directly over DURAFLEX™.  Pulling directly over will damage the flexible socket.
  2. There are three possible methods for pulling outer frames:
    • Apply several panty hose over the DURAFLEX™ while it is still on the mold.  Saturate with silicone spray.  The outer frame can then be pulled.
    • Use latex balloon or pva bag.  Apply stockinettes or vacuum forming hose over latex balloon or pva bag.
    • Pull the DURAFLEX™ as usual and do all necessary buildups.  Next, make a plaster cast of the DURAFLEX™ including buildups.  Refill this new cast, and pull the outer frame directly over the positive mold.  After proper cooling and removal, the outer frame is suitable for use with the DURAFLEX™.
Preparing for Laminating
 
For Most Laminating Techniques:
  1. Do the proper buildup.
  2. Pull nylon (stockinette) over the mold.
  3. Pull a pva bag over the mold.
  4. Ready to laminate.
If you use an Acrylic Resin or set your resin very hot, use this laminating technique:
  1. Do the proper buildup.
  2. Put a thin layer of petroleum jelly over the mold.
  3. Pull a pva bag over the mold and seal the bag.
  4. Put a lay-up material over the mold and pva bag.
  5. Then pull another pva bag over this.
  6. Ready to laminate.
Please contact us if you have any questions.
 
Best Regards,
 
Steve Hall
Account Manager
Guard Industries, Inc.
800-535-3508