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Jaipur Foot Manual
Jaipur Foot Manual
Jaipur Foot
This manual has been developed to be used as a guide along with the video to impart knowledge on fabricating a good quality Jaipur Foot. The manual has to be used with the accompanying video, which would enhance the quality and standardisation of Jaipur Foot the Foot which is the most popular in India.
Mobility India
1st & 1st A cross J.P. Nagar 2nd Phase Bangalore 560 078, India Email: mail@mobility-india.org
Introduction
With the rising number of amputees all over the world, the demand for Jaipur Foot has increased tremendously. Other than India, the Jaipur Foot is currently being used in many countries like Sri Lanka, Bangladesh, Cambodia, Vietnam, Afghanistan, Mozambique etc. While the demand of foot is growing rapidly, the Indian Production Units are not capable enough for catering such a large growing demand.Therefore, there is a huge gap between the ever increasing demand and supplies. Until now, the process of manufacturing Jaipur foot has been taught by apprenticeship method only. Foot makers and Limb fitters from different parts of the world come to Indian town Jaipur to have short-term training in foot making or sometimes Indian technicians go overseas to train. Quality of such training and foot produced by the trainees is always a big issue. Often Jaipur Foot earns adverse criticism due to its poor quality.
Introduction
The process is very simple but has small details missing, any of such details may reflect on the quality of the final product. All foot looks like Jaipur Foot but are not Jaipur Foot not even functionally - mainly due to fabrication fault. Besides optimum use of foot also depends on the knowledge and skills of the prosthetist who uses the Jaipur Foot in making of the prostheses. There are no reference literatures or audiovisuals available on how to make Jaipur Foot. This video and manual with proper training will help the trainees to learn to produce better quality of Jaipur Foot. The manual is a technical presentation of foot fabrication process aiming at the foot makers mainly to serve as reference book and help in quality control. It clearly describes the various stages of Jaipur Foot making as well as the material specification, equipments and tools used in the process.
Space at the bottom of following pages is for the trainee to take note in their own language. Seeing the demand, attempt will be made to translate it in other languages.
Introduction
Structural Components of Jaipur Foot:
Carriage Bolt Ankle Block External Covering Heel Block Forefoot Block Black Tyre Cord Toes
Flat Position Groove for the head of the bolt Flat head upside down
Top surface
Front surface
Upper Surface
POP Powder Paint brush Vaseline Tri square Spanner Scissor Hand Saw Die
Marked Foot
Tool with 3 mm teeth to Smoothening ridges create 3 mm deep groove with rasp file
Ankle
Sagittal
3 planes
Forefoot
Hindfoot
Foot in 3 parts
Ankle
Hindfoot
Vertical line at ankle Joining vertical lines
Forefoot
Marking of 3 planes
10 mm Drill at centre
Bottom of heel block Back of forefoot block and front of heel block Bottom of forefoot block.
4
4. Vulcanising
5. Finished Foot
10 mm drill on top
Fixing nails
10mm x 2/2.5 cm thick Cutting with sharp knife 3 layers of MCR blocks
Making MCR surface rough with rasp file (pre-condition before gluing)
Knife outwards
Layers of MCR strips usually 1 more strip than MCR heel block
Applying glue Joining the strips Cutting of block as per size of pattern
MCR toes
Coating over heel block Coating MCR forefoot block Coating over toes.
Cut 3 cm wide strips of Black Cushion Compound (BCC). Tightly wind strips to cover all the blocks and toes individually. Make sure while wrapping that you are applying uniform pressure and there is uniform overlapping of BCC.
3 cm wide BCC Strip Wrapping around ankle block Wrapping around heel block
Reinforcing and preparing the forefoot block to be joined with heel block
3 cm strip of RCC
Cutting of extra RCC rubber Checking the air bubbles Adding extra strip to fill the gap
Vulcanisation
Vulcanising of Foot
Replace the repaired foot piece in die and close the die tightly. Place the die in Autoclave. This process of heating the rubber foot with steam is known as Vulcanisation. During vulcanisation soft and uncured raw rubber becomes ready to use & durable.
Closing the die again Tightening the nuts & bolts Placing the die in autoclave for vulcansiation Closing the autoclave
For Cooling
Vulcanisation
Vulcanising of Foot
Jaipur Foot is vulcanised in Autoclave under 23psi pressure of steam at 125 Celsius temperature. Leave the die for 20-30 minutes inside Autoclave for curing.
In Autoclave
Vulcanisation
Vulcanising of Foot
Remove the die from autoclave and keep it for 12 hours in a cooler place for cooling. Do not open the die before it is fully cooled as this may cause air bubbles in rubber thus destroying the look, shape and strength of foot piece. Open the die and remove the foot piece slowly. While removing, do not damage the thread of the bolt.
Opening of die after vulcanisation Vulcanised Jaipur Foot Removing the foot from the die with care Tool to prevent damage of the thread
Vulcanisation
Vulcanising of Foot
Trim extra rubber with a very sharp knife to have a better finish. While trimming make sure that the knife does not go deep because in that case it will expose black rubber underneath. Once it is trimmed Jaipur Foot is ready to be fitted with socket and socket extension to make a prosthesis.
Vulcanisation
Vulcanising of Foot
One can make Jaipur Foot with various types of attachment or bolt assembly to fit any kind of prosthetics technology. It is the most popular foot in India and it will remain so till better alternatives come but experience says it might take ages. So till then, let us go on making good quality Jaipur Foot that would help Persons who do not have a leg, to be in the society as an important active equal member. Checking whole surface and finish.
A step forward
Jaipur Foot
The dream foot for millions The dream foot for millions
Annexure A
Black cushion compound ( unvalcanised rubber compound MRF code 7401203), Tyre cord ( rubberised rayon/ Nylon cord CRF 70x500; MRF code 7311400/7321400, Black tread compound MRF code 7403303 & Skin compound ( unvulcanised skin colour rubber compound)
1.
Madras Rubber Factory Ltd(MRF) 826 Taraporetower Anna Road, Chennai- 600032 Tamil Nadu , India
3.
Asia Rubber Mill Railway Road Gurgoan, Haryana- 122001, India Rajasthan Rubber Industries F-141 IP Industrial Area Kota- 324005 Rajasthan, India
4. Sundaram Industries Ltd. Rubber Factory (TVS) Post box number 6 Usilampatti Road,Kochadai Madurai-625016 Tamil Nadu - India Rubber Solution ( Dunlop Solution) 1. Dunlop India Ltd. 57B Mirza Ghalib Road Kolkatta, West Bengal India-700016 2.
Microcellular Rubber 1. Mahaveer Rubber Industries 48, Industrial Area Bais Godam, Jaipur Rajasthan- 302005, India
Drill Machine, Band Saw, Grinder etc. 1. Machine tools & traders NR Road, Bangalore, India 2. Polytech Mechanical Industries Ahmedabada, Gujarat India Batlibal & Company Pvt. Ltd V.B.,Gandhi Marg, Fort P.O. Box -190A Mumbai-400023, India
Aluminum Dies 1. Om Engineering Works A-12, Gayatri Nagar Sodala, Jaipur, India 2. S.K. Engineering Works 54- Paras Ram nagar Dher ke Balaji Jaipur- Rajasthan, India
3.
Auto Clave Machine 1. Time Surgicals Near Ajmer Pulia Hathoj, Jaipur, India 2. Nat Steel Equipments Pvt. Ltd Mumbai, India
For any further assistance in training and procuring tools, machinery, material, Jaipur Foot, Dies Prosthetics/Orthotics components contact:
MOBILITY INDIA
1ST & 1ST A CROSS J.P. NAGAR 2ND PHASE BANGALORE 560 078, INDIA TEL: +91 (080) 649 2222 or 649 4444 EMAIL: e-mail@mobility-india.org Website: www.mobility-india.org
Thank you to all who assisted us to complete this manual, especially members of Jaipur Foot Production Unit of Mobility India.