Conformable material for an orthotic device and method of making same
A conformable material for an orthotic device including a plurality of fibers each including a plurality of filaments encapsulated by a first thermoplastic material. A second thermoplastic material is configured to bind the plurality of fibers and form the conformable material.
1. A method of manufacturing a conformable material for an orthotic device, the method comprising the steps of:
heating and melting a first thermoplastic matrix material to form a plurality of sheets of the first thermoplastic;
heating and melting a second thermoplastic material to form a plurality of sheets of the second thermoplastic material;
sandwiching a sheet of filaments between the plurality of sheets of the first thermoplastic material;
sandwiching the sheet of filaments and sheets of first thermoplastic material between the plurality of sheets of the second thermoplastic material; and
heating and melting the sandwiched sheets to form the conformable material for an orthotic device.
2. The method of claim 1 further including the step of cutting the conformable material into a plurality of stands.
3. The method of claim 2 further including the step of braiding and/or weaving the plurality of stands together.
4. The method of claim 3 further including the step of heating and melting the braided stands to form the conformable material having a predetermined shape.