Workshop Materials
Workshop Solutions and Materials for Orthotics, Footwear Manufacture and Prosthetics
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Materials for Orthotics and Prosthetics
The field of orthotics and prosthetics (O&P) has moved well beyond leather, wood, and steel. Today, Australian clinicians, technicians, and manufacturers can choose from a wide range of modern materials—each bringing specific strengths to improve function, comfort, and durability. This guide summarises the key options used in orthotic and prosthetic applications, from natural products to advanced synthetics, textiles, metals, and resins.
Decision-Making Tools for Material Selection
- Patient profile: age, weight, health, occupation, activity level, climate, funding/insurance.
- Material properties: firmness, flexibility, rigidity, adjustability, strength, fatigue resistance.
- Environment: exposure to sweat/body fluids, temperature swings, moisture, risk of corrosion.
Natural Materials
Leather
Durable, breathable and naturally water-repellent. Common in straps, suspension cuffs and certain orthoses for its shock control. Can be bulkier than modern synthetics and less durable when frequently soaked.
Cork
Renewable, lightweight and resilient. Often blended with rubber or thermoplastics. Used for arch supports, forefoot extensions and as a stable base layer.
Synthetic Materials
Thermoplastics
- Polypropylene: rigid, impact-resistant; body jackets and AFOs.
- Polyethylene (PE): variable densities; flexible socket interfaces and splints.
- ABS: strong and stiff; reliable for structural components.
Foams and Gels
- Polyurethane foams: durable, good shock management; arch supports and high-impact areas.
- EVA foam: lightweight, easily thermoformed; insoles and cushioning layers.
- Silicone gels: soft tissue protection; distal end pads and gel liners.
Carbon Composites
Carbon fibre reinforced plastic (CFRP) delivers excellent strength-to-weight ratios. Favoured for high-performance prosthetics and responsive orthotic elements—ideal for active users and sports applications.
Textiles
- Nylon: flexible and durable; socket laminations and orthotic reinforcement.
- Fibreglass: strong with useful elasticity; multi-layer reinforcement.
- Kevlar: very high tensile strength and impact resistance; sockets and high-stress zones.
Metals
- Stainless steel: high stiffness, corrosion resistance; joints and structural supports.
- Titanium: lightweight yet strong; implants and prosthetic frames.
- Aluminium: light and easily machined; uprights and componentry.
- Copper: malleable; small fittings such as rivets and screws.
Chemicals and Resins
- Styrene: used in plastics/resins; requires strict handling controls.
- Acetone: common solvent; use with PPE and good ventilation.
- Epoxy resins: high tensile strength and flexibility; strong bonding and laminations.
- Polyester resins: cost-effective; more brittle than epoxy, suited to lighter-duty use.
Quick Comparison Table
| Material | Key Properties | Typical O&P Uses |
|---|---|---|
| EVA Foam | Lightweight, thermoformable, shock absorption | Foot orthoses, insoles, posting layers |
| Polypropylene | Rigid, impact-resistant, heat-mouldable | AFOs, spinal/body jackets |
| Carbon Composite (CFRP) | High strength-to-weight, energy return | Dynamic prosthetic feet, stiffeners, shells |
| Silicone Gel | Skin-friendly cushioning, pressure relief | Gel liners, distal end pads, protection |
| Leather | Breathable, durable, natural shock control | Straps, cuffs, traditional orthoses |
| Epoxy Resin | Strong, durable laminations | Socket lamination and bonding |
Workshop Safety
- Ventilation & filtration: control fumes and dust at source.
- PPE: gloves, masks/respirators, eye protection, hearing protection where needed.
- Training & handling: regular instruction and adherence to safety data sheets.
Algeos Australia: Materials & Conversion
Algeos Australia supplies one of the widest ranges of O&P materials available - foams, composites, metals, plastics and adhesives. With in-house cutting, splitting and laminating, we can deliver almost any size, density or laminate configuration to support both custom builds and production runs.
Aortha – Orthotic Materials Technology
Aortha unifies Algeos materials and components under a trusted brand. The range includes EVA in multiple densities, carbon composites, thermoplastics, transfer papers for AFOs, lower-limb orthotic joints and prosthetic components. As the industry shifts towards CAD-CAM and 3D printing, Aortha continues to advance EVA, plastics and PU formulations compatible with leading orthotic CAD-CAM systems - supporting Australian clinics and labs with reliable, repeatable outcomes.
Workshop Materials
Workshop Solutions and Materials for Orthotics, Footwear Manufacture and Prosthetics
Materials for Orthotics and Prosthetics
The field of orthotics and prosthetics (O&P) has moved well beyond leather, wood, and steel. Today, Australian clinicians, technicians, and manufacturers can choose from a wide range of modern materials—each bringing specific strengths to improve function, comfort, and durability. This guide summarises the key options used in orthotic and prosthetic applications, from natural products to advanced synthetics, textiles, metals, and resins.
Decision-Making Tools for Material Selection
- Patient profile: age, weight, health, occupation, activity level, climate, funding/insurance.
- Material properties: firmness, flexibility, rigidity, adjustability, strength, fatigue resistance.
- Environment: exposure to sweat/body fluids, temperature swings, moisture, risk of corrosion.
Natural Materials
Leather
Durable, breathable and naturally water-repellent. Common in straps, suspension cuffs and certain orthoses for its shock control. Can be bulkier than modern synthetics and less durable when frequently soaked.
Cork
Renewable, lightweight and resilient. Often blended with rubber or thermoplastics. Used for arch supports, forefoot extensions and as a stable base layer.
Synthetic Materials
Thermoplastics
- Polypropylene: rigid, impact-resistant; body jackets and AFOs.
- Polyethylene (PE): variable densities; flexible socket interfaces and splints.
- ABS: strong and stiff; reliable for structural components.
Foams and Gels
- Polyurethane foams: durable, good shock management; arch supports and high-impact areas.
- EVA foam: lightweight, easily thermoformed; insoles and cushioning layers.
- Silicone gels: soft tissue protection; distal end pads and gel liners.
Carbon Composites
Carbon fibre reinforced plastic (CFRP) delivers excellent strength-to-weight ratios. Favoured for high-performance prosthetics and responsive orthotic elements—ideal for active users and sports applications.
Textiles
- Nylon: flexible and durable; socket laminations and orthotic reinforcement.
- Fibreglass: strong with useful elasticity; multi-layer reinforcement.
- Kevlar: very high tensile strength and impact resistance; sockets and high-stress zones.
Metals
- Stainless steel: high stiffness, corrosion resistance; joints and structural supports.
- Titanium: lightweight yet strong; implants and prosthetic frames.
- Aluminium: light and easily machined; uprights and componentry.
- Copper: malleable; small fittings such as rivets and screws.
Chemicals and Resins
- Styrene: used in plastics/resins; requires strict handling controls.
- Acetone: common solvent; use with PPE and good ventilation.
- Epoxy resins: high tensile strength and flexibility; strong bonding and laminations.
- Polyester resins: cost-effective; more brittle than epoxy, suited to lighter-duty use.
Quick Comparison Table
| Material | Key Properties | Typical O&P Uses |
|---|---|---|
| EVA Foam | Lightweight, thermoformable, shock absorption | Foot orthoses, insoles, posting layers |
| Polypropylene | Rigid, impact-resistant, heat-mouldable | AFOs, spinal/body jackets |
| Carbon Composite (CFRP) | High strength-to-weight, energy return | Dynamic prosthetic feet, stiffeners, shells |
| Silicone Gel | Skin-friendly cushioning, pressure relief | Gel liners, distal end pads, protection |
| Leather | Breathable, durable, natural shock control | Straps, cuffs, traditional orthoses |
| Epoxy Resin | Strong, durable laminations | Socket lamination and bonding |
Workshop Safety
- Ventilation & filtration: control fumes and dust at source.
- PPE: gloves, masks/respirators, eye protection, hearing protection where needed.
- Training & handling: regular instruction and adherence to safety data sheets.
Algeos Australia: Materials & Conversion
Algeos Australia supplies one of the widest ranges of O&P materials available - foams, composites, metals, plastics and adhesives. With in-house cutting, splitting and laminating, we can deliver almost any size, density or laminate configuration to support both custom builds and production runs.
Aortha – Orthotic Materials Technology
Aortha unifies Algeos materials and components under a trusted brand. The range includes EVA in multiple densities, carbon composites, thermoplastics, transfer papers for AFOs, lower-limb orthotic joints and prosthetic components. As the industry shifts towards CAD-CAM and 3D printing, Aortha continues to advance EVA, plastics and PU formulations compatible with leading orthotic CAD-CAM systems - supporting Australian clinics and labs with reliable, repeatable outcomes.