A great alternative to itchy, expensive carbon fiber braid! Coyote Composite, made from basalt filament is a safe, tough material for composite sockets and AFOs. Also relatively easy to cut and finish compared to other materials.
A few years ago we made the switch to using basalt braid
(Coyote Composite) rather than carbon fiber for our laminations.
We did this for a more flexible tougher lamination, but ended up with other benefits as well. Mainly a safer material that doesn’t itch the way carbon does, and it costs less.
It does laminate almost exactly the same, but there are some subtle differences in saturation. We have a lot of tips and tricks to help ensure you can laminate easily and effectively with Coyote Composite, and we can save you money.
Now Is the time to provide a safer work environment and save money.
Composite on outside of lay-up
RESIN Coyote Composite works with typical prosthetic resins and saturates much better than carbon.
SATURATION AND LAMINATING Because of its superior saturation it’s important to prevent resin starvation. Lamination starvation will cause frayed edges.
FINISHING Coyote Composite finishes easily except in cases of starved laminations. Use sharp tooling at slow speeds to finish. In some cases, you may need to wet-sand.
RELIEVING Coyote Composite is heat- and flame-resistant and isn’t damaged by heating. It allows for limited adjustment based on the type of resin used.
SAFETY Because of the inert nature of basalt, it is not a carcinogen. Also, Coyote Composite is between 9 and 16 micrometers in diameter, which is too large to be an inhalant risk. Basalt also causes significantly less skin irritation.
Composite on inside of lay-up
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We typically use two layers of basalt, with basic nylon stockinette in different order depending on the finish, and carbon tape over the distal end.
Epoxy resin run full vacuum at 20 to 24 in/HG until everything is saturated and cured.
Very important to follow resin manufacturers instructions for proper measurements and mixing
Use the roughest sanding cone to take the edge down to the trim lines.
Finish with Tycro wheel. If you want more do a wet sand with scotch bright.
Use medium scotch bright wheel, buff outside to inside, inside to outside, smoothing and rounding off edges.
When polishing and finishing slow speed may give better results.
Layups are effected by the type of resin used.
Modified Acrylic; thinner, easier to saturate, fast cure
Epoxy Resin; stronger, clearer, thicker, slower cure time
Epoxy works well for heavier and more active people.
Epoxy resin manufacturers typically recommend a heat bag.
Acrylic modified epoxy resin run full vacuum at 20 to 24 in/HG until everything is saturated. When done stringing and walking away turn vacuum down to 10 to 15 in/HG.
– Vacuum & Resins with Coyote Composite
Tips on vacuum, resin and lay-up
Finishing Edge Using Coyote Composite
Coyote Composite edges finish smoother and tend to be less jagged than carbon fiber.
Use equal amounts of Coyote Composite in place of carbon fiber in your existing layups, or you can try one of Coyote Designs sample layups.
How you lay it up will also greatly change the strength weight and flexibility.
Brad Davis, CPA CTP - Coyote Design's Central Fabrication Asst. Mgr. tells how he likes to finish the edge of a prosthetic socket made out of Coyote Composite in this Tech Tips video.
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