Process for manufacture of laminate shells

1. A method for making a spinal orthosis, the method comprising the steps of:

providing a first laminate material comprising a flexible foam material and a substantially rigid plastic sheet material sandwiched between a pair of soft flexible sheet materials and bonded together to yield a unitary and substantially rigid first laminate material;

forming an anterior support from the first laminate material, the anterior support being formed by heating the first laminate material under conditions of pressure to soften the first laminate to a pliable state, cutting the first laminate to a desired shape to yield a first pattern corresponding to a desired shape of the anterior support, providing a first form corresponding to a desired configuration of the anterior support and positioning the first pattern on the first form in a pliable state, applying a negative pressure to conform the first pattern to the first form, and cooling the conformed first pattern to yield the anterior support;

providing a second laminate material comprising a flexible foam material and a substantially rigid plastic sheet material sandwiched between a pair of soft flexible sheet materials and bonded together to yield a unitary and substantially rigid second laminate material;

forming an posterior support from the second laminate material, the posterior support being formed by heating the second laminate material under conditions of pressure to soften the second laminate to a pliable state, cutting the second laminate to a desired shape to yield a second pattern corresponding to a desired shape of the posterior support, providing a second form corresponding to a desired configuration of the posterior support and positioning the second pattern on the second form in a pliable state, applying a negative pressure to conform the second pattern to the second form, and cooling the conformed second pattern to yield the posterior support.

2. The method of claim 1 , wherein the step of cutting the first laminate occurs prior to the step of heating the first laminate under conditions of pressure.

3. The method of claim 1 , wherein the step of cutting the first laminate occurs after the step of heating the first laminate under conditions of pressure.

4. The method of claim 1 , wherein the step of applying a negative pressure to conform the first pattern to the first form, comprises applying a plastic bag around the first form having the first pattern thereon and applying a negative pressure to the bag.

5. The method of claim 1 , wherein the anterior and posterior support members are configured for placement around a torso of a user and have sufficient rigidity to serve a support function, while also having a degree of flexibility sufficient to permit substantially unrestricted contractions and expansions of the torso of the user associated with breathing.

6. A method for making an orthosis, comprising the steps of:

providing a laminate material comprising a flexible foam material and a substantially rigid plastic sheet material sandwiched between a pair of soft flexible sheet materials and bonded together to yield a unitary and substantially rigid laminate material;

forming a body support from the laminate material, the body support being formed by heating the laminate material under conditions of pressure to soften the laminate to a pliable state, cutting the laminate to a desired shape to yield a pattern corresponding to a desired shape of the body support, providing a form corresponding to a desired configuration of the body support and positioning the pattern on the form in a pliable state, applying a negative pressure to conform the pattern to the form, and cooling the conformed pattern to yield the body support.

7. The method of claim 6 , wherein the step of cutting the laminate occurs prior to the step of heating the laminate under conditions of pressure.

8. The method of claim 6 , wherein the step of cutting the laminate occurs after the step of heating the laminate under conditions of pressure.

9. The method of claim 6 , wherein the step of applying a negative pressure to conform the pattern to the form, comprises applying a plastic bag around the form having the pattern thereon and applying a negative pressure to the bag.

10. The orthosis of claim 6 , wherein the body support member is configured for placement around a torso of a user and has sufficient rigidity to serve a support function, while also having a degree of flexibility sufficient to permit substantially unrestricted contractions and expansions of the torso of the user associated with breathing.