Always nice to get something new.

KeithB

Resident Half Fast Machinist
My prostheticist called and let me know that he got all the necessary OKs from the govt and my insurance to get me a new leg!

I have three appointments over the next three weeks for them to make a mold, make a test socket, and then a final (hopefully) fitting. The socket I have now has been shimmed and padded and it still doesn't fit well, the limit to how much I can do now is not my strength but my prosthetic.

The new one is supposed to attach by a different means, it uses a vacuum method that is supposed to fit more uniformly snugly with no pressure points and an easier way to attach/remove. It is also supposed to have a bendable ankle with some adjustable hydraulic valving to "tune" the spring/bend rate. Harder for newbies to learn to use but capable of giving a far more natural gait.

Nice to have something to look forward to!
 

Brad

Benevolent Overlord and site owner
Staff member
Not just new, not just better, but something that can drastically impact daily function.

Amazing what they can do today. Way beyond the old peg leg.
 

quicksylver

Well-Known Member
Hope it works for you ...being physically comfortable makes a huge difference in ones quality of life..
 

Pistolero

Well-Known Member
Good to hear that they have improved prosthetics, better technology needs to filter into all
areas where it can help people, not just glamorous things.

I have a friend with a missing foot, and I have repaired his prosthetic a couple of times over the years.
I have always wonder why nobody makes an nice sandwich carbon fiber light weight prosthetic?
The heavy ordinary ones cost enough to buy enough high tech, low weight, high
strength materials to make 25 of them. Maybe low weight isn't a real benefit.

One fix was a broken grade 2 bolt on the ankle joint. I was surprised that they didn't use at least a $0.15
grade 5 bolt, and a grade 8 would have cost maybe $0.50 or so for a $3-4K prosthetic. I wonder if the field
isn't more of an artisan sort of thing rather than much engineering. I am sure that the fitting
and sculpting of the socket takes a great deal of skill and training to make it really work properly. I could
make one light and strong but wouldn't have a clue how to fit it properly to make it comfortable, and
no doubt comfort is going to be way more important than strength or weight, as long as it doesn't break.
But my friend's did break twice in the last 25 years.

Maybe you can CNC mill one out of solid aluminum. :D :rolleyes:

I hope you get to where my friend is. Most folks who meet him have no clue that
he has a prosthetic, and when my bad knee acts up, he walks better than I do.

Bill
 

fiver

Well-Known Member
being able to move your body into a squared up balanced position will add a bunch of strength and dexterity to everyday tasks.

this is great news.
 

KeithB

Resident Half Fast Machinist
The fitting is done by putting whatever minimum padding is to be used on my stump, (right now I wear a 6mm thick gel sleeve that rolls on like a condom) and then a plaster cast is made over that. When that dries it is used as a mold to make a test socket out of clear plastic. The second appointment is a test fit of the socket to my stump, where pressure points, etc. can be spotted through the clear material. The last appointment is to adjust the finished socket and foot combo to the right height and orientation. The last time they just took off the hardware from the bottom of the socket and bolted it to the new socket and tuned it to fit. This time I will be getting a new ankle/foot so I can keep the old socket/foot around intact as a backup. (Maybe the better half can use it for a planter...)

So far my sockets have been made from a resin impregnated carbon fiber tube. They are pretty light and once used to it I hardly notice it much anymore. It's kind of like wearing a knee high boot, rigid ankle and all. There is some flex in the foot, the foot piece is carbon fiber and is shaped to provide a split leaf spring toward the toe and a single leaf spring in the heel. But without ankle flex it's hard to stand up from a chair and do several other things easily.
 

Pistolero

Well-Known Member
Sounds a good bit more advanced composite technology than my friend's foot prosthesis. His is all pink fiberglass, seems custom shaped. Pretty heavy.
Carbon fiber is very light and very strong, seems a better choice when you are making a critical device and which will always be quite expensive due
to the great deal of skill and time involved in making it properly. It would seem that raw material cost would be a pretty small part of the overall cost.
That gel padding sounds really good. I have used some gel gloves for bike riding and they are a real improvement in comfort on a long ride compared
to foam padding. My friend keeps his old prosthesis around as a spare in case there is a problem with the newest one. He has used them a couple
of times, but says the stump changes over time and the old ones, while useable for temporary situations, don't fit properly any more. Watch out for
ankle bolts with no hash marks on the head. :D

Hope it is comfortable and more useful for you. As I get older, I realize more and more that we are just holding back the tide as best we can
in a battle we will never win, but which is well worth our very best fight.

Best wishes, sir.

Bill
 

KeithB

Resident Half Fast Machinist
Yes the stump changes over time, but the biggest changes are in the first couple of years. This will be my third socket, it's been three+ years since the original procedure. Not much size change since my visit six months ago. Apparently that is one of the factors in how often/how much insurance/Medicare will cover.

All the screws in my prosthesis are hex socket head cap and set screws. All are torqued down to some predetermined value by the prostheticist, he has a nice little torque wrench that takes the proper hex bits. (I've been tempted to "borrow" it when he isn't looking, LOL)

My current gel sleeve is 6mm thick in the front, 4 mm thick in the back, color coded so I can easily tell which is which. It has a fabric outer layer and a plate on the end that has a barbed spike (imagine the barbs on an air hose fitting) with 7 barbs that lock into a latch in the base of the socket. I have a number of fabric "socks" of different thicknesses that I have to wear to make sure my stump fits tightly in the socket. A tight socket is like a hydraulic cylinder with the valve shut, it makes things rigid and prevents abrasion from rubbing. Over the course of a day I typically add one to three plies of socks as my stump shrinks slightly from pressure. With the right number of socks I get four or five clicks into my socket. When I hit seven clicks I have to add socks to keep from walking on the base of my stump. Of course it also effects my left leg length, which effects my gait, and so forth.

My new prosthesis uses a vacuum versus barb/latch type system. The new gel sleeves have no fabric outer layer, and the socket has a gel inner liner. The gel/gel contact makes a tight seal, with an air valve to let air in the bottom to break the seal to take off the socket. Supposed to fit more snugly, more consistent leg length.

I'll find out more tomorrow when I get the cast of my stump made.
 

KeithB

Resident Half Fast Machinist
Just a couple more weeks. I hope it lets me walk on unpaved ground easier. I just bought a fairly large piece of land to build a shop on and I haven't been able to walk the boundaries.
 

Pistolero

Well-Known Member
More technology that I have previously been aware of. Frankly, my friend may be hooked up with a shop doing outdated
work, or I haven't kept up. I seen him regularly, but the topic of his prosthesis doesn't come up much. It has been at least
10 years since I worked on one of his, so maybe he has totally different style now, too, although it looks the same. He was with
me at Oshkosh, wearing shorts, superficially looked the same. What you describe wounds technologicallyvfar ahead of what I
worked on last time. His foot was attached with one large bolt as a pivot and attach. Part of his hinges out, velcro
strap to hold it together. Beyond that rough description, I don't know how it really works.

Sounds like the are doing a lot to make them more functional and comfortable. My friend gets around amazingly well, but
he lost his foot in a preteen accident and is now in late 50s so a lot of years of practice.

Hope your new one makes life easier and more comfortable. It is good to hear when newer technology is used to make people's
lives easier and better.

Bill
 
F

freebullet

Guest
Good luck, Keith!

On a hobby/need level I've layed up tons of laminates, mostly fiberglass. It's quite an interesting process.

If the new one don't work out maybe we can lay up a spring type replacement. It'd be more like step, boing, step....
 

Pistolero

Well-Known Member
After building an entire airplane out of sandwich composites, I tend to want to apply them to any lightweight,
stiff application where it seems reasonable. Sounds like a high technology composite prosthesis, which is just cool.

And I hope, effective at the desired job.

Bill
 

smokeywolf

Well-Known Member
Keith, anxious to learn the outcome of your new prosthetic. With a background in engineering and machining and a bit of study in anthropometrics, prosthetics has always sparked quite a bit of interest for me.
My next door neighbor came back from Operation Desert Storm with nary a scratch and two months later laid his motorcycle down on the San Diego Fwy, was run over by the car behind him and lost his leg below the knee. He's been on a prosthetic for around 25 years now.
 

KeithB

Resident Half Fast Machinist
Finally got a little spare time so I thought I'd post a follow up and get some closure on this. About a month ago I got my new prosthetic leg and it's wonderful. It fits just about perfectly, nice and snug and very positive. My old prosthetic doesn't fit nearly as well and I just couldn't pad it with enough socks to make it fit properly and still get it on. I could hold my leg out and shake it and my prosthetic would rattle back and forth, my stump was like a clapper in a bell.

My old prosthetic also has a rigid ankle. The foot form in it is made of carbon fiber and shaped with cantilever springs in the heel and toe so there is some overall springiness and the ability to provide for a reasonably natural rollover from heel to toe as you walk, but the rigid ankle means that I am standing on my toes when I get up from a chair, and also when I try to squat down and pick up something from the ground. Very unbalancing!

My new prosthetic has a hydraulic ankle with a range of motion that is slightly less than what a human ankle usually has, with two adjustable valves to control how quickly the ankle flexes forward and backward. Of course there are also numerous adjustments to control the direction and attitude of the basic foot, so it can be adjusted for (literally!) toe-in or -out, pitch, yaw, and roll. I am knock kneed and so my lower leg points outward, these adjustments allow for the prosthetic to be adjusted to my physiology. Once tuned and adjusted, my new leg feels really natural. The one thing it lacks is any springiness.

(An aside to the technical folks: my old prosthetic was a spring system with no damping; my new one is a damped system with no springiness, a superior system would be a spring-and-dashpot system with springiness and damping, such as that on a car with springs and shock absorbers. But I digress...)

My old prosthetic requires that I wear on a 6mm thick gel sleeve (it has a cloth outer layer to prevent stretching) with a barb on the end that mechanically latches into the base of the socket. To take off my socket I have to press in a button to release the barbed end. It is simple and quick and I still use it at night when I need to get up and use the restroom. I can put it on in the dark in just a few seconds and for the few steps it takes to make it to the head it is fine.

My new prosthetic is held on by air pressure. I wear a 4mm gel sleeve (no cloth outer layer) on my stump. My prosthetic has a carbon fiber outer socket, a semi-clear soft vinyl inner liner, and sandwiched between the two is a black gel sleeve. I wear a cloth sock of the proper thickness over the gel leg sleeve so that there is about a 2" band of gel exposed at the top, and when I step into the socket I just roll up the black outer sleeve and press it onto the gel leg sleeve to form an air tight seal. There is a simple push button air valve on the side of the socket; when I stand up any residual air is forced out of the valve. To take off the socket I have to roll down the black sleeve to break the seal and then press the button to equalize the pressure. It is a VERY secure method of attachment.

I wore my new leg for three days with no problems. Then I took it off on day four and unrolled the gel sleeve and poured about a half cup of bodily fluid and lots of bits of skin out of it. All the callous that I had built up on the end of my stump had softened and come off, and I had a raw spot about the size of a coffee cup. I put some antibiotic on it and dressed it and since it was a Friday I had to wait until Monday to call my prostheticist. Meanwhile I got the walker back out and spent the next ten days confined to getting around the house in my rolling office chair and using the walker to get to the restroom.

My prostheticist told me that apparently what had happened was that there was a small unfilled void at the bottom of the socket and while I was up and walking I had squeezed all the air out, but when I sat down and took the weight off my stump had pulled back a little bit and the end had formed a near perfect vacuum. This literally sucked the fluid out of my stump and peeled off the hardest and least flexible skin on the end. A hickey you don't want to get!

Once I was able to wear a prosthetic again I used my old one until I could get in for a refit of my new one earlier this week. My guy tweaked a few rub spots (a little heating and reforming of the soft vinyl inner layer took care of that) and also put a wad of lamb's wool down into the base of the socket. It fills the void and even when compressed it traps enough air to keep from forming too high a vacuum. I also learned not to dangle my leg or let it hang, and to hit the air valve to let air pressure in the base when I sit down. I can feel the pressure change when I do that; I need to learn what the new sensations mean when wearing my new prosthetic.

I have been wearing my new leg for almost a week now and have been up and working with no problems so I think that obstacle is overcome. Now that I am mobile again I can get back to meeting with contractors, etc to get going on building our new shop.

Old prosthetic on left, new on right. Note button latch on left, air valve on right.
prosthetic4.jpg

Three layer construction. carbon fiber outer, vinyl inner, gel sleeve between
prosthetic2.jpg

Sleeve for old prosthetic. Note barb on end.
prosthetic5.jpg

Gel sleeve I wear for new prosthetic
prosthetic7.jpg

Here I am wearing new prosthetic
prosthetic8.jpg

Here is the ankle with all its adjustments
prosthetic3.jpg
 

Brad

Benevolent Overlord and site owner
Staff member
Interesting. Lots of engineering in those prosthetics.
I was thinking it was above knee, not below knee.

Hope this isn't interfering too much with the new shop plans.