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Abstract

A flexible tubular prosthetic pylon is formed by resin impregnated carbon fibers. The wall of the tubular pylon has a uniform thickness over most of its length to make the pylon relatively rigid. However, an annular band of the pylon wall adjacent one end is relatively thin to form a flexible portion at that end. During fitting of the pylon, the end of the pylon opposite the flexible portion is trimmed to a desired length. Since substantially all of the flexure of the pylon occurs in the flexible portion, trimming the opposite end does not affect the flexure characteristics of the pylon. The pylon is made by table rolling layers of pre-impregnated fibers around a mandrel, with a reduced number of layers in a band adjacent one end forming the relatively thin wall. The resulting laminate and mandrel are then placed in a mold having mold surfaces that replicate the outer surface of the pylon. The mandrel is expanded radially to force the laminate against the mold surfaces, and the mold is then heated to cure the resin. Finally, the laminate and mandrel are removed from the mold, the mandrel is made to radially contract, and the mandrel is removed from inside the laminate to complete the prosthetic pylon.

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First Claim