Introduction and Objectives Results

In 2005, the polystyrene (PS) casting system was developed Circumference Chart Most Height Chart
Elastic bag Non-Elastic bag accurate level
by Wu Yeongchi, utilizing polystyrene foam beads attached to 327

Circumference (mm)
52
control Elastic bag Non-Elastic bag

Height (mm)
325
a vacuum pressure pump to create a negative cast, for the 51
control
323 50
Transtibial prostheses. 321 49
Problem Statement : According to the report of ISPO 319 48

Vancouver in 2007, the PS casting tends to shrink the 317 47

negative cast, although in some cases there were induced 315 46

tight fitting. Objective: This study aims to Surface roughness Chart Durability Graph
Non-Elastic bag 8
optimize the PS casting by 3 Plaster based
7
2.5 Reduce Elastic bag

Displacement (mm)
(PS Rq / POP Rq)
determining the accuracy,

Roughness index
6
roughness Increase Non-Elastic bag
2 5
durability and surface 1.5 roughness 4

roughness, then comparing 1 Elastic bag

3
2
with the common plaster 0.5 1
Figure 1. Polystyrene Casting
casting method. 0 0

4.9

9.8

49
0

14.7

19.6

24.5

29.4

34.3

39.2

44.1

53.9

58.8

63.7

68.6

73.5

78.4
Force (N)
Methods Stable Dummy 170mg /80kpa 170mg /50kpa 170mg /20kpa
Plaster Base Casting 28mg /80kpa 28mg /50kpa 28mg /20kpa
Casting accuracy [Test1], Durability [Test2] and Surface
roughness [Test3] have been evaluated by; casting a cylindrical Discussion
POM* with fixed parameters. Best durability Satisfaction rating score
Table 1. Casting specimen Best surface 170mg/Ela./80kpa
6
28mg/Ela./20kpa 5
170mg/Ela./50kpa 6 : Excellent
Material Circumference Diameter Height 4 5 : Good
POM 325 mm 103 mm 400 mm plaster base casting 3 170mg/Non-Ela./80kpa 4 : Normal
* POM: Polyoxymethylene (Solid engineering plastic) 2 3 : Fair
Best accuracy 1 2 : Bad
PS casting parameters are shown table 2. 170mg/Ela./20kpa 0 170mg/Non-Ela./50kpa 1 : Very bad

Evaluated different conditions are shown table 3.

Accuracy
Table 2. PS casting parameters 170mg/Non-Ela./20kpa 28mg/Ela./50kpa
Grain size (mm) 0.5-1.2 Durability
28mg/Non-Ela./80kpa 28mg/Non-Ela./50kpa
Density (mg/cm3) High: (170) Low: (28) Fine Surface
28mg/Ela./80kpa
Bag material Elastic TPU** Non-elastic HDPE
& Thickness (mm) ( 0.03 ) (0.17) Conclusion
Vacuum pressure (kPa) High: (80) Mid: (50) Low: (20) Recommended Original PS casting
* *TPU: Thermoplastic Polyurethane condition by Dr. Wu
Ranking Score (%)

condition
100%
100
Table 3. Variable conditions of PS casting Elastic bag Non-Elastic bag
80
1. Density 170 / Elastic/ vacuum 80kpa 7. Density 28 / Elastic/ vacuum 80kpa 60 Plaster base
2. Density 170 / Elastic/ vacuum 50kpa 8. Density 28 / Elastic/ vacuum 50kpa 40
casting

3. Density 170 / Elastic/ vacuum 20kpa 9. Density 28 / Elastic/ vacuum 20kpa

4. Density 170 / Non-elastic/ vacuum 80kpa
5. Density 170 / Non-elastic/ vacuum 50kpa
6. Density 170 / Non-elastic/ vacuum 20kpa
[Test1] Accuracy:
Cast models taken by variable
conditions of PS casting also
includes POP casting, were
compared with specimen table 1.
[Test2] Durability: Tests were
conducted similar to the stress-
strain test. The cast brim was
compressed 0 - 80N by a steel
rod (Fig.2)
[Test3] Surface roughness:
evaluated by calculating the
Root Mean Square roughness
(Rq) by following ISO 4288
assessment rules & ISO 3274
using a Dial gauge. (Fig3).
Rq: Root Mean Square roughness
𝟏 𝑳
Rq = ‫׬‬ 𝒇(𝒙) 𝟐 𝒅𝒙
L: Scanning evaluation length (40mm x 3 times)
𝑳 𝟎
x: Sampling distance (0.5mm)
TEMPLATE DESIGN © 2008
20
10. Density 28 / Non-elastic/ vacuum 80kpa
0
(Original PS casting condition by Dr. Wu) 170mg 170mg 170mg 28mg 28mg 28mg 170mg 170mg 170mg 28mg 28mg
11. Density 28 / Non-elastic/ vacuum 50kpa /80kpa /50kpa /20kpa /80kpa /50kpa /20kpa /80kpa /50kpa /20kpa /80kpa /50kpa
12. Density 28 / Non-elastic/ vacuum 20kpa
Best result in this study
Force Best (accuracy & durability)
0-80N
Best (accuracy & surface)
Φ= 30 mm
Measure plastic Hydrostatic casting (need
deformation compressible casting
condition)
References
Weighing scale
1. Yeongchi Wu, and other editors, CIR casting system for making
Fig 2. Durability test Transtibial sockets, 33(1): 1–9, March 2009, Center for
Cast model moves forward by using
International Rehabilitation, Chicago, and 2Northwestern
University Feinberg School of Medicine, Chicago, USA
the handle.
2. Thanh, N. H. Field Experience with Sand-casting and Wu-
Casting system in Vietnam, 12th World Congress of the
International Society for Prosthetics and OrthoticsVancouver,
Dial gauge
accuracy Canada, July 29 –August 3, 2007
0.05mm
Acknowledgements
This research was supported by Sirindhorn School of Prosthetics and
Orthotics, Faculty of Medicine Siriraj Hospital, Mahidol University.
Fig 3. Surface roughness test We would like to thank Assoc. Prof. Dr. Nisarat Opartkiattikul
director of Sirindhorn School of Prosthetics and Orthotics, the
research committee and our supervisors; Mr. Kazuhiko Sasaki and
Ms. Prawina Sutdet, who provided insight and expertise that greatly
assisted the research.

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