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Limb-itless Prototype Presentation: Silicone Molding Process Improvement

In our project update, we explore the process of silicone molding for limb prosthetics. We tested materials, faced challenges, and proposed solutions for a stronger final product. The incorporation of fibers and modification of the molding process are key focuses.

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Limb-itless Prototype Presentation: Silicone Molding Process Improvement

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  1. Prototype Presentation Limb-itless Group 4 Chris Bruce, Anna Chen, and Grant Hofmeister

  2. Since the last update • Finished wooden mold precursor at the Hobby Shop. • Attempted to make plaster mold of the silicone liner. • Tested the MED-4091 silicone elastomer. • Made prototype with molding rubber.

  3. Hobby Shop Pictures

  4. Prototype • Molding process worked marginally well. • Plaster used was too soft and cracked easily. • Silicone did not reach all parts of the mold. • Material used tore easily. • Solutions • Need to find a higher strength plaster. • Process must be modified for MED-4091 and for high temperature curing.

  5. Improvements for Final Product • Use better silicone material. • Adding fibers in correct orientation. • Making durable plaster molds. • Modify the molding process for the new material. • Accommodate for the pin.

  6. MED-4091 Silicone Material • Sample had the properties we were looking for. • However it was more viscous than expected. • Molding process needs to be modified for this. • It will make it easier for fiber alignment. • Silicone processing cannot have sulfur or it will hinder the curing process.

  7. Incorporation of Fibers • Viscosity of MED-4091 should allow us to hand place the fibers onto mold. • Brush thin layer of silicone onto interior mold. • Place fibers onto silicone. • Brush another thin layer of silicone on top of the fibers.

  8. Mold • Experienced difficulty making first plaster mold. • In prototype, used wooden model as inner mold. • Obtained new plaster with higher strength and faster drying times.

  9. Molding Process • For prototype, we poured silicone into the mold which was upright. • For final product, we plan to invert the mold so that we can brush onto the inner mold. • The outer mold will then be pressed down to complete the process. • Then cure the liner at 150º C.

  10. Next Steps • Make silicone sheets with and without fibers. • Perform tensile tests. • Make new molds. • Make new liner with new materials.

  11. Gantt Chart

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