A cast is made, extended with a soft plastic sheet and tied in a tapered manner. In the center of this form is a steel reinforcement rod. In this photo, former STAND volunteer holds the bottom part of the extension so as to restrict the plaster from leaking out. The plaster dries in five minutes.
Here the cast is shaped to make it appear like a natural leg. Chisels are used to shave the plaster and get it as smooth as possible. Note the dip on the mold, which is a key pressure point on the back of the leg, which allows for a firm comfortable fit for the amputee.
Marc and a technician covering, or “laminating” a finished plaster mold with a High Density Polyethylene (HDPE) pipe, soft enough to take the shape of the mold. Once it is left to cool for an hour, we break up the plaster inside by hitting the very resistant HDPE pipe with metal bars.
Shaping HDPE plastic into prosthetic limb.The lower cut is where the leg will bend for a comfortable sitting position. The other side is smoothly notched inward so the kneecap will rest on it. Despite modern technology available, broken glass still proves to be the best tool for shaving.
Marc checking that the prosthetic limb is comfortable for the patient. We put a thin cotton sock over the stump for comfort and to eliminate perspiration. We also add thin, 3mm foam on the inside edges for comfort. Once this is done, a small leather belt is fastened to the top of the prosthetic.
The last step: Marc heating up the bottom of the prosthetic so as to add the rubber foot. The foot is layered with different rubbers imported from India. The prosthetic limb is now ready. It is lightweight, very durable and resistant to hard hits, and the foot will last 2 years before being replaced.
A new patient practices walking on her new limb. They need encouragement, reassurance and gentleness to help them cope with the drastic change. Without any major obstacles, a patient could come in and leave the same day with their custom-made prosthetic limb.
After a long day, we recall the obstacles we encounter here: electrical power cuts, shortages of water, lack of sponsorship and materials. But seeing even just one person walk again, and experiencing their restored dignity, makes our struggle worth it all!
