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VERTEX® INTRODUCTION

VERTEX® is a revolutionary new composite material designed for the orthotic, prosthetic and pedorthic industry that provides maximum strength with minimum weight. Your imagination is the limit. VERTEX® composite laminates combines high volume fraction of carbon and glass fibre with thermoplastic resins to form a fully consolidated laminate with maximum strength andstiffness at a cost effective price. As a result, it is a highly versatile thermoplastic composite with many applications such as foot orthotics, rocker plates, stiffeners, shanks and reinforcements.

FABRICATION INSTRUCTIONS FOR FOOT ORTHOTICS• Requires pump, press and prepared cast• If possible have cast slightly warm for optimal molding • Make sure cast is completely dry as moisture reduces temperature

• Use appropriate size VERTEX® blank. • 3.5”x 7”, 4”x 8”or 5”x 9” in either 1 mm or 1.5 mm or cut appropriate size from VERTEX® sheet

• Trim proximal corners to help eliminate wrinkles at heel cup• Can use scissors on 1 mm or tin snips on 1.5 mm

• Place VERTEX® Plate in Oven at 400° F on Teflon sheet to prevent sticking * Follow appropriate heating instructions on page 26

• Transfer from oven to vacuum as fast as possible

• Hand form medial arch and heel cup while vacuum forming for optimal results* Follow appropriate forming instructions on page 21

• Trim edges of orthosis to reduce sanding time

SPECIAL ATTRIBUTES: • Light weight • Highly impact resistant • Can be stored at room temperature • Material is reformable after molding • Environmentally Friendly • No use of solvents during processing

PROPERTIES:• Fibretype: Carbon/Glass• Fibre Volume Content: 45% Fibre• Fabric: Filament glass• Polymer type: Thermoplastic resin

    Eq. Flex Bending    Modulus (GPA) Rigidity (N * M2)(1mm) 40 4(1.5mm) 40 12typical testing results

TECH TIPS: • Cuttable with scissors or snips• Sticks to itself when heated

THERMOPLASTIC COMPOSITES

METHODS OF FORMING:By Hand• Use a pair of Crusader Flex heat resistant gloves to press/massage the material into the right shape• Warming cast can increase working time• Cast should be completely dry, any moisture will cause VERTEX®

to cool too quickly• Requires rapid transfer to cast (2-3 seconds optimum) 

Vacuum forming• Use a vacuum frame with a silicone or gum rubber bladder • Place the hot material on the plaster mould and evacuate air• Warming cast can increase working time• Cast should be completely dry, any moisture will cause VERTEX®

to cool too quickly• Requires rapid transfer from heating to forming tool (2-3 seconds optimum)

METHODS OF HEATING:Infrared Oven• 400° F• 30 – 60 seconds, depending on thickness• Maximum 3 minutes• Smoke indicates overheating• When material is like “play dough” it is ready for forming• Spot modification can be done with a heat gun

Convection Oven• 400° F• 1 – 3 minutes, depending on thickness• Maximum 4 minutes• Smoke indicates overheating• When material is like “play dough” it is ready for forming• Spot modification can be done with a heat gun

GRINDING THE MATERIAL:• Grinding VERTEX® is done by avoiding heat during grinding• If grinding correctly there will be little fiber fly because it will stick to the resin• Use sandpaper with large grains (i.e. 36 grit)• Grind VERTEX® continuously instead of grinding in only one spot

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MATERIAL INFORMATION:• 50% of fibers are in 90° to

the long side of the sheet

• 50% of the fibers are 0° to the long side of the sheet

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BLANK SIZES: 1mm 90mm x 180mm (3.5” x 7) . . . . . . . . . . . .2VP137 . . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .1mm 109mm x 200mm (4” x 8) . . . . . . . . . . . . .2VP148 . . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .1mm 130mm x 230mm (5” x 9) . . . . . . . . . . . . .2VP159 . . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .

SHEET SIZE:1mm 620mm x 1000mm (24.4” x 39”) . . . . . . . . .2VS1 . . . . . . . . . . . 5+ Blanks . . . . . . . . . . 10+ Blanks . . . . . . . . .

BLANK SIZES:1.5mm 90mm x 180mm (3.5” x 7) . . . . . . . . . . . .2VP1537 . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .1.5mm 109mm x 200mm (4” x 8) . . . . . . . . . . . . .2VP1548 . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .1.5mm 130mm x 230mm (5” x 9) . . . . . . . . . . . . .2VP1559 . . . . . . . . . . 50+ Blanks . . . . . . . . . . . . 100+ Blanks . . . . . . . . . . .

SHEET SIZE:1mm 620mm x 1000mm (24.4” x 39”) . . . . . . . . .2VS15 . . . . . . . . . . 5+ Blanks . . . . . . . . . . 10+ Blanks . . . . . . . . .

THERMOPLASTIC COMPOSITES

Thinnest in the industry

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...CONT.  FABRICATION INSTRUCTIONS FOR FOOT ORTHOTICS• Initiate grinding with coarse sandpaper• Grind in a continuous motion

• Finish orthosis with topcover, posting or modifications as required

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• Cut appropriate size and thickness of VERTEX® from sheet

• Outline template on VERTEX® using chalk or grease pencil

• Cut out using scissors or tin snips

• Grind cut out using standing grinding technique

• Completed Morton’s Extension

• Can be used for stiffeners, rocker plates, composite sole plates or shanks.

MANUFACTURE OF MORTON’S EXTENSION • (For Morton’s neuroma and Hallux rigidus)

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VERTEX® PRICING