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By: Alex Brett, R.T.O.(c)

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Prosthetic foot shell or life cast 40 Durometer urethane Urethane pigment 25 lb/cu ft. Flexible urethane foam Replicator silicone 5 Durometer silicone Cast sealer Mixing cups Mixing sticks 1 Disposable brushes 1oz Felt, Nylon stockinette Renia PUR primer Aquaseal adhesive and leather for sole

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When working with urethane foams and rubbers: always wear gloves and assure there is adequate ventilation (or use a suitable respirator). Avoid contact with skin. If you are ever unsure of a material, consult the MSDS prior to using. *All the products used in fabrication of this partial foot are completely safe as long as they are used properly and with care.*

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We will start by fabricating 2 negative molds of a prosthetic foot shell or a life cast. 1 with Renew materials silicone replicator 1 with Renew materials 5 durometer silicone

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We will now seal the cast, pigment the urethane and brush on four layers. A nylon should be added for reinforcement on the fourth layer.

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We will now scuff the surface of the socket, and fit it into the replicator mold. After that we will pour 25lb flexible foam into the mold to create a basic foot shape.

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Once the foam has cured, we will demold, clean up and reduce the overall thickness of the forefoot by approximately 1 cm.

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We will then brush 3 more coats over the socket and foamed forefoot to encapsulate the foam. This foam is used so that the foot will be lightweight yet still flexible. Pure urethane can be used but this will result in a very heavy partial foot.

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We will now take the 5 durometer silicone negative, pour urethane into it, and pull it over the foot to give the finished piece a high definition appearance

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Once the urethane has cured, demold the foot and smooth the transition with a 180X cone.

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Rotate 1 final layer of urethane (minus the toes) to seal the transition up.

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It is best to post cure in the oven @ 50C for 4-6 hours. This will assure the urethane is fully cured and acheives maximum strength.

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We will then buff the exterior with 320X sandpaper to take the shine off.

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Remove foot from cast and trim as desired

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Your foot is now ready for a test fitting! Urethane can be can cut and modified easily with scissors, and a 180X sanding cone.

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Always fabricate partial feet 1 size under sound side. They tend to appear larger, so 1 cm under sound side is usually well received. Aquaseal adhesive can be used to repair or glue a sole to your urethane partial foot. Renia PUR primer works great to prep urethane surfaces that have cured fully between steps.

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