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Grinding orthotics made from carbon graphite composites

Discussion in 'Biomechanics, Sports and Foot orthoses' started by Craig Payne, Jul 17, 2010.

  1. Craig Payne

    Craig Payne Moderator


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    I have never been a big fan of the carbon graphite materials as they are a **** of a material to have to adjust and grind. Any lab people out there care to comment on how they manage to grind them at the lab during fabrication?
  2. Kursh Mohammed

    Kursh Mohammed Active Member

    Hi Craig,
    Which carbon graphite materials do you use?

    We use the TL-2100 or the XT sprint. We have a heavy duty cutter, very similar to this one Algeo's sell,

    Once it's been cut, we have a heavy duty grinder - the grinding belt is really strong. This really does make life really easy. Though not matter what carbon material is used it's always a tricky area!
  3. Craig Payne

    Craig Payne Moderator

    I don't actually use any .... its just the wife keeps getting me to adjust, renew etc orthotics for her clinic :bash: .... I just hate it when its a carbon graphite composite!

    Was hoping for some pearls in how to deal with the material... :drinks
  4. Craig:

    I wouldn't be grinding that stuff without a respirator...you don't want to be the first case of a podiatrist dying of graphitosis from grinding graphite composite orthoses! http://www.flints.co.uk/pdffiles/graphitepowder.pdf

    Tell Mimi to stick to polypropylene....and save your lungs!

    Attached Files:

  5. Ian Linane

    Ian Linane Well-Known Member

    Hi Craig

    I used to make devices out of pure carbon fibre sheets utilising the "wet-up-lay2 technique (very labour intensive per pair) and I also used carbon composites. For both of these I used a heavy duty grinder and it worked well, followed by some decent sanding paper to take off the remaining fibres. With the right grinder it was a matter of getting used to the angle of grind and pressure applied. I manufactured these in a well ventilated area and was okay.

    When I moved to Brighton I carried on making them in my large workshop but could not ventilate it enough and was fed up with the heavy duty mask so stopped making my own.

    I'd agree with Kevin as when I worked in my workshop I found a couple of hours of the grinding would leave me uncomfortable in the back of the throat. That said, making small adjustments with a good mask on might not be as much a problem.

  6. Admin2

    Admin2 Administrator Staff Member

  7. Graham

    Graham RIP


    I've switched from XT to Performance RX from PARIS. It's a NYLON based material I believe!
  8. Kursh Mohammed

    Kursh Mohammed Active Member

    Hi Graham,

    The Performance RX material from Paris - do you have a website of the company that I could contact about the material? Thank you.
  9. joejared

    joejared Active Member

    Actually, labs at least in my network that made the switch from carbon graphite actually switched to direct milled acetal (delrin) in order to maintain strength and low thicknesses. Machining characteristics are actually better than polypropylene but about 2 1/2 times more costly.
  10. brevis

    brevis Active Member

    It took me a long time to work out carbon fibre composites. It wasnt until Atlas gave me a few pointers that I was able to produce consistent results.

    I have multiple belts of various grits. I tend to keep the heavy (40 grit) just for carbon fibre. Continually rotating the belts depending on material etc is the best for the grinder motor (so I have been told by a mate who is a fitter and turner). My guess a slower RPM is also more desirable.

    The composites requir a different grinding technique. I have found that applying the direct edge at a perpindicular angle is the most effective. Its usually the heel counter that "bunches up" around the positive cast that needs the most muscle .

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