Prosthetic Fabrication
Virginia Prosthetics is proud to distinguish itself from many other O&P providers in that we have our own central fabrication facility located at our Roanoke office. In today’s business model where many companies have turned to outsourcing most or virtually all of their orthotic and prosthetic fabrication to manufacturing companies located elsewhere in the country, Virginia Prosthetics has always believed that in order to provide the highest level of patient service, we must perform our own fabrication.
Having an in-house fabrication facility allows us to eliminate the majority of errors that are inherent with communicating detailed information long distance from one person to another, i.e. from the practitioner who actually evaluates and measures the patient to the production worker who has never seen the patient and must make the device without the benefit of the practitioner’s supervision and input.
At Virginia Prosthetics, the same highly trained practitioner who evaluates and measures you also fabricates or works hand-in-hand with the technician who fabricates your device. This process ensures that the orthotic or prosthetic device you receive will have the highest degree of intimate fit and finish available.
In addition to the quality and fit advantages, manufacturing in-house allows us to produce and deliver the finished device with minimal interruption to the schedule, and any necessary adjustments or modifications can be made immediately during the fitting appointment. This allows the patient to return to their everyday lives that much more quickly.
The Making of a Prosthesis
The purpose of an external prosthetic is to replace the functional and cosmetic attributes of a missing body part. At Virginia Prosthetics, we concentrate on prosthetics for those patients who have lost an upper or lower limb. The prosthetics industry has seen more growth in the engineering and development of the mechanical functioning of prosthetic devices in the last 20 years than it has since the first prosthetic device was fitted in ancient Egypt more than 2,000 years ago.
Virginia Prosthetics is proud to be an industry BETA test facility. This means that of all the O&P providers nationwide, we are one of a handful that prosthetic component manufacturers utilize in the development and evaluation of new prosthetic devices. This positions us to be aware of new products long before they come on the market and to already have an intimate working knowledge with these products when they are available.
Evaluation and Measurement
As discussed in the section on our website, “What should I expect,” when you are ready for your first prosthesis you will meet with one of our certified and experienced practitioners to evaluate your current condition and assess what it is that you need in order to fully regain your life, your independence, and any special goals you have set. During this appointment we will measure you for what is termed a “diagnostic socket”, which is a temporary socket that allows us to evaluate the fit and to determine any modifications that need to be made to your “definitive” or long term socket.
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Using the latest technology, we obtain a digital image of the residual limb using a laser imaging device called "T-Ring". As the ring is passed over the residual limb as it transmits precise measurement data to the computer CAD program. |
An alternative method of obtaining a replica of a patients residual limb is by “casting”. Though this method has generally been replaced by digital imaging, we find that for some patients, casting is still the best method available. |
Creating Your Limb
In order to make a prosthetic it is first necessary to create a mold of your residual limb. It is imperative that this mold be accurate in every aspect so that your prosthetic will be both functional and comfortable. The first stages in the fabrication of prosthesis are similar, whether it is a “diagnostic” or a “definitive” socket. Only the first step, making a positive duplicate of your limb, will be different depending on whether we used CAD or casting to obtain the dimensions.
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If we cast you using the casting technique,we will fill the hollow cast impression with plaster to make a “positive” of your limb. |
If we used the T-Ring to take dimensions, we then load the digital CAD file into our mold carver and starting with a block of special silicone impregnated foam, we then carve a "positive" image of your limb. |
Shaping the Mold
Once we have a positive form, the next step is the careful modification by removal and or addition of material so as to accommodate any special fitting requirements and provide the most intimate final fit possible. Your practitioner will do these modifications themselves since they are familiar with your own unique fitting requirements.
Socket Fabrication
When your practitioner is confident that your mold is correct in all aspects, we are then ready to make the socket that will act as the all important connection between your residual limb and your prosthetic device, whether that is an upper or a lower extremity. Depending on what type of socket is desired will determine what specific material and the fabrication method are used.
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If the socket is to be a thermo plastic then the process will involve vacuum forming a thermoplastic over the final mold. |
If the socket is to be a laminated type, then we will use woven carbon fiber and resins to form the finished socket. |
Once the raw socket is formed, the next step is to cut what are called “trim lines”, which are the proximal edges of the socket. After that it is sent through our finishing room where the socket receives final sanding, smoothing, and polishing.
Prosthesis Assembly
When fabrication of the socket is finally complete it then travels back to the technician’s bench for fitting and attachment of the mechanical 
components of your prosthesis. Once all this is done, the technician and your practitioner will inspect the initial alignment of the components and perform a final inspection. Once we are confident that your prosthesis is finished and ready to be fitted it is placed in the delivery area and the front office is notified to contact you for an appointment to get your prosthesis.
Delivery
Whether it’s a new amputee getting their first leg, or one of our many existing patients replacing an older prostheses that no longer fits, every time we deliver a prosthesis everyone at Virginia Prosthetics gets a great feeling of accomplishment and satisfaction, knowing that we can help people to help themselves, regain their lives, and do whatever it is they want to do.
