JAIPUR FOOT MANUAL

This manual has been developed to be used as a guide along with the video to impart knowledge on fabricating a good quality Jaipur Foot. The manual has to be used with the accompanying video, which would enhance the quality and standardisation of Jaipur Foot the Foot which is the most popular in India.

For Jaipur Foot Video and Manual contact:

Jaipur Limb Campaign Mobility Indiast st404 Camden Road, 1 & 1 A cross

ndLondon N7 0SJ UK J.P. Nagar 2 PhaseEmail: Bangalore 560 078, India

Email: [email protected]@jaipurlimb.org

Jaipur Foot Jaipur Foot

A project of Jaipur Limb Campaign, UK&

Mobility India

Supported by Community Fund, UK

THEJAIPUR LIMBCAMPAIGN-UK


The process is very simple but has small details missing, any of such details may reflect on the quality of the final product. All foot looks like Jaipur Foot but are not “Jaipur Foot” not even functionally - mainly due to fabrication fault. Besides optimum use of foot also depends on the knowledge and skills of the prosthetist who uses the Jaipur Foot in making of the prostheses. There are no reference literatures or audiovisuals available on how to make Jaipur Foot. This video and manual with proper training will help the trainees to learn to produce better quality of Jaipur Foot. The manual is a technical presentation of foot fabrication process aiming at the foot makers mainly to serve as reference book and help in quality control. It clearly describes the various stages of Jaipur Foot making as well as the material specification, equipments and tools used in the process.

With the rising number of amputees all over the world, the demand for Jaipur Foot has increased tremendously. Other than India, the Jaipur Foot is currently being used in many countries like Sri Lanka, Bangladesh, Cambodia, Vietnam, Afghanistan, Mozambique etc. While the demand of foot is growing rapidly, the Indian Production Units are not capable enough for catering such a large growing demand.Therefore, there is a huge gap between the ever increasing demand and supplies. Until now, the process of manufacturing Jaipur foot has been taught by apprenticeship method only. Foot makers and Limb fitters from different parts of the world come to Indian town Jaipur to have short-term training in foot making or sometimes Indian technicians go overseas to train. Quality of such training and foot produced by the trainees is always a big issue. Often Jaipur Foot earns adverse criticism due to its poor quality.

IntroductionIntroduction

IntroductionIntroduction

Space at the bottom of following pages is for the trainee to take note in their own language. Seeing the demand, attempt will be made to translate it in other languages.Space at the bottom of following pages is for the trainee to take note in their own language. Seeing the demand, attempt will be made to translate it in other languages.

IntroductionIntroductionStructural Components of Jaipur Foot:

Carriage Bolt

Ankle Block

Heel Block

Forefoot Block

External Covering

Toes

Black Tyre Cord

What is Jaipur Foot?In technical terms, Jaipur Foot is an improved version of a conventional SACH (Solid Ankle Cushion Heel) foot rather to say a dynamic foot with shorter/flexible keel. It is basically a soft multi axial foot, meaning that it is flexible along multiple axes. The greatest advantage of Jaipur foot over SACH foot is that it allows all natural movement of the foot including Dorsiflexion movement and looks like a natural foot. Jaipur foot means a glimmer of hope for millions who have paused in their journey due to amputation and helps them to take - A Step forward Every Day.

What is Jaipur Foot?

Components of Jaipur Foot

1. Wooden Keel for Ankle RegionIt is made out of laminated layers of wooden block that provides anchorage to carriage bolt (10 mm) made of steel with thread on top.

Upright position

Carriage bolt

Nails to fix carriage boltOpposite Layers of wood

Flat Position

Groove for the head of the bolt Flat head upside down

1. Ankle Block

Components of Jaipur Foot

Components of Jaipur FootComponents of Jaipur Foot

Short Wooden keel of Jaipur Foot . The ankle block has layers of wooden pieces glued together with grains in different directions. It holds the

0prosthesis on top of the foot. Bolt has to be 90 or at right angle.Advantages:1. Greater strength in comparison to a normal block of similar size.2. Light weight3. It prevents splitting because of carriage bolt and good bondage.

Provides dorsiflexion and planter flexion movement

Grains in opposite direction

The hind foot region consists of a block of Microcellular Rubber (MCR) protected by strong rubber shell and tyre cord.The MCR block is capable of the following:

A. Deflection, torsion or other movements associated with squatting or walking on uneven surfaces.

B. Provides closer to normal gait to the user.C. Absorb shocks while landing on heel during

walking.D. It holds the wooden ankle block and MCR forefoot

together

Top surface Front surface

Ankle Block

Heel Block

Forefoot Block

1. Ankle Block

2. The Hindfoot Region (Heel Block )Components of Jaipur FootComponents of Jaipur Foot


4. The external covering: The external covering is the main barrier between MCR blocks and environment. This covering is made of vulcanized rubber which provides the following benefits:

A. Flexible and durable.B. Waterproof.C. Natural look.

Components of jaipur footComponents of jaipur foot3. The Forefoot Region & Toes:

The forefoot region is made of MCR rubber which is stiffer than that of the heel block. This block is also protected by hard rubber and tyre cord. It allows the natural movement of foot. It holds the hind foot and toes together. Forefoot block is usually composition of two/ three MCR slabs glued together.

Forefoot block is first covered with tyre cord which prevents external shell from cracking and internal blocks from falling out. Later it gets covered with cushion rubber for protection and good cosmesis. Toes also made out of small pieces of MCR and then covered in same process.

Upper Surface


Tools, Machinery & Materials

It is always better to have the following hand tools and equipment to make a good quality Jaipur Foot:

1. Hand shear to cut aluminum.2. Steel ruler or scale3. Bench vice4. Hammer5. Sharp knife6. Nylon paint brush7. Scissors8. Spanners to close and open the die.Tri square

Spanner

Hand Saw

Scissor Rasp file

Tool to make groove

Die

10 mm Carriage bolt

Vaseline

POP Powder

Paint brush

Tools & MachineryTools, Machinery & MaterialsTools, Machinery & Materials

1. Vaseline or any vegetable oil. 2. Aluminum sheet or cardboard3. Wooden plank of 10 cm wide. 4. White adhesive or Fevicol.5. Carriage bolt (10mm diameter) 6. POP - 2kg (for each mould) 7. MCR sheet shore A35 & A45. 8. Toluene or any other cleaning 9. Rubber adhesive solution. 10. Vulcanizing cement 11. Black Cushion compound.(BCC) 12. Red Cushion Compound(RCC) 13. Black Tread compound.(BTC)14. Tyre cord (nylon)

9. Container or bowl for POP paste10. Tri-square 11. Sketch pen or lead pencils12. Scraping tool, this can be made

out of 2mm thick mild steel sheet with tooth of 3mm

13. Wood saw14. Wooden chisel15. Wooden file (rough & smooth)16. Bench grinder17. Drill Machine18. Autoclave (steriliser)19. Band Saw (optional)

Drill machine

Autoclave

Safety gadgets

Bench Grinder

Tools & Machinery

Materials:

Tools, Machinery & MaterialsTools, Machinery & Materials


The aluminum Jaipur Foot die is the most important tool for fabrication of Jaipur Foot without which one cannot make a Jaipur Foot. The die was developed with the help of local craftsman in Jaipur who were experienced in the art of statue making using the ancient technique of sand casting. The uniqueness about these dies is that they are made in all sizes and obviously for both right & left feet. Jaipur Foot can also be fashioned slightly narrower for woman's feet and for those who prefer to wear shoes or sandals.

3 piece Aluminium die with hinge

Uncured rubber is soft and becomes brittle in very cold weather and tears easily in moderate heat, so it is advised to store rubber in cool & dry place (22 -24 Celsius) not directly exposed to sun light. Rubber should be stuck together to check adherence equally & stretched to check the elasticity. The plastic film which covers the tyre cord and the cushion compound should not be removed prior to sticking it on. It is advised to use uncured rubber, within 6 months from date of manufacture. Rubber adhesive solution and vulcanising cement are petroleum based products. They dry fast, therefore their containers should be tightly shut when not in use.

Fridge to store uncured rubber

Selection & Storage of Material:

The Aluminium Die:



POP Pattern & Aluminium Template

Two types of dies are currently used in manufacturing the Jaipur Foot, they are the three-pieces and four-pieces die. Three piece die (preferably with hinges at bottom) is preferred as it leaves less marks on the finished foot. At the time of buying new dies, one should check for a die that can be disassembled easily. It is better if the die has steady pins.The high quality finish of the die not only gives the Jaipur Foot its natural appearance but also enables the foot piece encased within it to be heated to high temperature so that all the rubber is fused together to achieve a very durable foot.

2 sides of hindfoot and ankle

Base of whole foot

Forefoot

3 piece die with hinge 3 piece die without hinge

The Aluminium Die:Tools, Machinery & MaterialsTools, Machinery & Materials

A Pattern is needed as a guide to make the blocks as replica. It will be used as reference for shaping of rubber & wooden blocks. Use a painting brush to apply some Vaseline on the inside wall of the die. This ensures easy removal of the POP block from the die at a later stage after the pattern making is complete. Make sure that the vaseline spreads all over the inside wall. Pour POP solution and keep the die aside for 24 hours to allow POP to set and become hard. Open the die carefully and remove the plaster mould from it.

Applying baseline inside the die Pouring POP solution inside the die Separation of die once POP sets well.

Required for POP setting

POP Patterns:POP Pattern & Aluminium TemplatePOP Pattern & Aluminium Template

Hold the mould against rotating working disc or any flat surface. Separate the toes by knife slowly & carefully. Once the toes are separated from mould, smoothen the edges with the help of rough rasp file or wire mesh.

Cutting of last 3 toes Cutting of 2nd toe Cutting of all the toes and smoothing the edge.

POP Patterns:

Place the mould on flat surface. Mark front to back and side to side mid points. Join the respective midpoints as shown in figure below:

A B

C

D

o90 vertical line at ankle & heelTop of the ankle block Joining 4 reference lines

POP Patterns:POP Pattern & Aluminium TemplatePOP Pattern & Aluminium Template

POP Pattern & Aluminium TemplatePOP Pattern & Aluminium Template

Repeat the previous process to mark a line through centre of heel on back side. Extend these lines all around the mould. Draw pencil lines parallel to both horizontal & vertical lines respectively at 10 mm apart. Draw 3mm deep grooves along the pencil lines marked in previous step with metal scrapper. The purpose of making groove along the pencil line is to create uniform gap of 3mm between die and mould. This gap will be filled by rubber to cover all the blocks used in making Jaipur foot. Once the scraping process is finished, you will observe grooves & ridges over mould surface. Smoothen the ridges using rough file so that the surface matches with grooves.The finished POP mould has uniform gap of 3 mm within the die.

Marking all around foot 10 mm apart

Marked Foot Tool with 3 mm teeth to create 3 mm deep groove

Smoothening ridges with rasp file

Before moving to next step let us clear the concept of planes passing through foot. These planes will guide us to divide foot into three functional components. The foot is divided into three planes,

Ankle

HindfootForefoot

Foot in 3 parts

Sagittal

POP Patterns:

POP Patterns:



3 planes

Plane 1--- Sagittal plane (Left & Right)Plane 2--- Transverse plane (Up & Down) Plane 3--- Frontal plane (Front & Back)

After getting smooth mould, mark the two planes of the foot. Horizontal line around ankle represent transverse plane, it is joining area of ankle block & heel block. Vertical line in front of ankle represent frontal plane, it is joining area of heel block & forefoot block. Draw a horizontal line around the ankle passing through both the malleolis. This line represents the area where movement will take place while walking. Keep a L- angle (tri-square) as shown in figure and draw a vertical line passing through mid ankle points to both inner & outer side of mould.

Marking of 3 planes

Hindfoot Forefoot

Ankle

Cut three planes to divide the mould into three blocks like 3 plane with the help of hand saw. After cutting mould with hand saw we get three blocks. These are:

POP Pattern in 3 pieces

POP Heel Block

POP Forefoot Block

POP Ankle Block

POP Pattern & Aluminium TemplatePOP Pattern & Aluminium TemplatePOP Patterns:

1. Ankle Block 2. Heel Block3. Forefoot Block

POP Pattern & Aluminium TemplatePOP Pattern & Aluminium TemplatePOP Patterns:

Joining vertical linesVertical line at ankle

Check upper and lower templates with the POP Ankle block pattern. Make sure they match. Drill a hole in centre point of upper and lower template. Repeat the previous procedure to make the templates for heel and forefoot block.

Bottom of heel block

Bottom of ankle block and top of heel block

4

Bottom of forefoot block.

Top of ankle block

Back of forefoot blockand front of heel block

10 mm Drill at centre

Place the POP ankle block on an aluminium sheet, draw outlines of upper & lower ends and also respective midpoints. Join respective midpoints with axis lines. Cut along the outlines to form the template. Smoothen the edges with aluminium file.

Top of ankle block pattern

Top template of ankle block

Bottom template of ankle block

Marking of bottom template using the POP ankle block

Making Of Templates:


Making Of Templates:POP Pattern & Aluminium TemplatePOP Pattern & Aluminium Template

Different Stages of FabricationDifferent Stages of Fabrication

1. Shaping of Blocks

2. Assembling Blocks

3. Covering with rubber

5. Finished Foot

4. Vulcanising

Take few wooden pieces of 10cm x 10cm and 10 mm thick. Stick 5 to 6 square pieces with fevicol according to height of POP ankle block. Take care that grains of two consecutive wooden planks should be in opposite direction. This gives extra strength to wooden blocks. Place the wooden block in carpenter vice or under any heavy object and leave for 12 hours for good bondage. Make sure that the wooden block is of same height as the POP block pattern.

Checking the height of wooden block with POP ankle block

Ankle BlockShaping of Blocks & ToesShaping of Blocks & Toes

Keep the top template of ankle block over wooden block such that axis lines on template match with diagonal lines on block. Mark the out line of template on block. Draw diagonal lines on upper & lower surface of block. Drill a 10mm vertical hole at the intersecting point of diagonal lines to a Shape the wooden block like the ankle block pattern with reference to top and bottom templates. Use hand saw to remove extra wood, once you get closer to the pattern, use wooden rasp file to get an exact shape & make the surface smooth. Keep POP pattern for reference. Wooden ankle block should be replica of POP pattern.

ccommodate carriage bolt (M10).

wooden ankle blockreplica/copy of POP ankle block pattern

Ankle BlockShaping of Blocks & ToesShaping of Blocks & Toes

Use 10 mm drill from top to ensure space for carriage bolt and 8 mm drill to make 2.5 cm x 0.5 cm x 0.5 cm groove at bottom. You can also use wooden chisel for making the same groove. This groove. Will be used as counter sunk for head of bolt. Carriage bolt is an ordinary M10 long steel bolt but flattened head with two small drilled holes to fix nails. Length of the bolt depends on size of the die. It usually 50 mm longer than the height of ankle block.

10 mm drill on top Creating groove at bottom of ankle block using 8 mm drill bit

Carriage bolt with flattened head

Ankle Block

Shaping of Blocks & ToesShaping of Blocks & Toes

Fixing nails

Hammer carriage bolt into the hole to ensure that the head of the bolt sits perfectly in the slot. Fix the carriage bolt with two nails. This mechanism helps to prevent rotation of carriage bolt.

Ankle Block


Fixing carriage bolt from bottom of ankle block.

Take 2 or 2.5 cm thick MCR Sheet of A35 sore hardness (Softer sheet). Cut 10 cm wide several strips of soft MCR sheet with a saw after proper marking. Clean it nicely with toluene or any other cleaning agent before applying glue for better bonding.

Cutting with sharp knife

3 layers of MCR blocks

10mm x 2/2.5 cm thick

Heel Block


Apply rubber solution/adhesive to both sides of strips which will be placed in between & to one side which will be on the top & bottom.

Making MCR surface rough with rasp file

(pre-condition before gluing)

Applying rubber solution / addessive on both the

surfaces. Joining of 2 MCR strips

Joining of 3 MCR strips

Heel BlockShaping of Blocks & ToesShaping of Blocks & Toes

One can make a device as shown in the figure below to ensure that different layers of rubber sticks well. Keep the glued rubber blocks in between wooden planks which are to be little pressed inside a bench vice. Ensure that rubber block is not pressed too hard in that case it will lose its property.

Wooden planks

MCR strips joined together

Ordinary bench vice

2 bench vices 30 to 50 cm apart


Time required

for bonding

Mark centre line on both faces of heel block using template. Draw outline of top & bottom template on respective faces. Make sure that centre line and axis lines marked on template are matching perfectly with rubber block.

Bottom of the heel block

Front of the heel block

Top of the heel block

Height as per size of POP pattern


Back of the heel block

Cut the rubber block into shape of POP heel block pattern. Keep the POP heel block pattern for reference. Initially shape the block with knife. Keep the knife outwards and once rough shape is achieved use Rasp file to get a better finish.

Finished MCRheel block

Top

Knife outwards

Bottom

Shaping the heel block


Repeat the previous procedure but here one should take MCR Sheet of A-45 sore hardness (harder than MCR used for heel). Cut the sheet into 10 cm wide strips.Clean it nicely with toluene or any other cleaning agent before applying glue for better bonding. Stick pieces together.

Layers of MCR strips usually 1 more strip than

MCR heel block

Forefoot Block


Cutting of block as per size of pattern

Applying glue

Joining the strips

Once the adhesive/glue is dry, cut rubber blocks which are 1 ½ times of POP fore foot block measurement in all respects. Draw a diagonal line along side of rubber block as shown in figure.Cut the rubber block along the diagonal line to form 2 blocks of similar measurements. We can use these blocks to make two forefoot blocks thus save the material.

oCutting at 45 angle

Forefoot BlockShaping of Blocks & ToesShaping of Blocks & Toes

2 MCR forefoot blocks out of 1 MCR block.

Place forefoot template and draw outlines on rubber block. Cut the rubber block with a sharp knife and shape it like POP forefoot block pattern, keep the POP pattern for reference, once the required shape is obtained smoothen the block with the help of rasp file.

Marking the bottom of forefoot block using

templateBack of forefoot block

(same template of front of heel block)

Use knife to shape like POP pattern

Forefoot BlockShaping of Blocks & ToesShaping of Blocks & Toes

Use file to give final shape

Use waste pieces of MCR A-35 sore hardness (softer) to make toes of foot. Shape great toe and four other toes using knife and rasp files. Place all the toes in die and ensure correct Size.

Making of toes using a rasp file.

5 toes out of MCR as per die size

MCR TOES:


Place all the blocks & toes in die to ensure correct proportions, size and uniform gap of 3mm between die and blocks. In this step, you have to make sure that medial arch is correctly carved on heel block and forefoot block.

3 mm gap between blocks and inner wall of die.

Wooden ankle block with carriage bolt

MCR heel block

MCR toes MCR forefoot block

Checking Of Mcr Blocks And Heel Block Inside The Die

Assembling of Blocks & ToesAssembling of Blocks & Toes

First of all, use paintbrush to spread thick coat of vulcanising rubber cement all over the blocks and toes. Ensure uniform coating.

Coating over toes.

Applying thick coat over ankle

Coating over heel block

Coating MCR forefoot block

Assembling Of Blocks & Toes:


Cut 3 cm wide strips of Black Cushion Compound (BCC). Tightly wind strips to cover all the blocks and toes individually. Make sure while wrapping that you are applying uniform pressure and there is uniform overlapping of BCC.

Wrapping around ankle block

3 cm wide BCC Strip

Wrapping around heel block

BCC Rubber CoatingAssembling of Blocks & ToesAssembling of Blocks & Toes

Wrapping around forefoot block

Repeat the previous process with Black Tread Compound (BTC) sheet, but make sure that this time plastic film is on top. Trace the out line by pressing finger against edge of die over BTC sheet and cut the sheet along the impression. One can also use a template to cut the BTC rubber but in that case one should have several sizes of templates in stock.

Marking on the BTC sheet using a template of whole foot.

Same as RCC piece

Assembling of Blocks & ToesAssembling of Blocks & ToesSole of Foot

To make good sole of the Jaipur Foot, place the red (preferably cinnamon or colour nearer to natural colour of the foot) cushion compound sheet on metal die. Ensure plastic film is downwards; mark the outline of foot over Red Cushion Compound (RCC) Sheet with thumb pressure against edge of the die. Cut the sheet with a pair of scissors along the outline. This becomes the outer cover of the foot it is more for cosmetic reason. One should keep in mind RCC does not give strength, it adds weight unnecessarily if it is overused.

Sole of the foot using RCC sheet

Using thumb pressure to get the marking RCC piece as per the size of the die.

Sole of Foot


Place the Red Cushion Compound sheet like shoe insole over the bottom surface of die. A long strip (approximately 55cm) of tyre cord of 3.7 cm width needs to be placed on top of RCC sheet. Tyre cord is a reinforcement material. It is used to tie different components of foot together & provides extra strength to foot like different tendons and ligaments of natural foot.

1 Tyer cord strip ½ width of heel

BCC over RCC with a tyre cord in between

Sole of FootAssembling of Blocks & ToesAssembling of Blocks & Toes

Stick another strip of tyre cord 50 cm by crosswise at mid-heel. Place the BTC foot pattern on top of the strips with the plastic film facing upward. The tyre cord strips are now sandwiched between the BTC and the RCC sole surface.Tear the tyre cord into five strips, one for each toe. These strips of tyre cord will be used to join each toe with forefoot block.

To hold heel block and ankle block together5 thin strips for 5 toes.

Assembling of Blocks & ToesAssembling of Blocks & ToesSole of Foot

Take another 3.7 cm width tyre cord (preferably nylon not rayon) and join Forefoot and Heel Block as shown in the figure. Make sure two blocks should not be separable after tying. Use BCC to fill up the gap between blocks.

Reinforcing and preparing the forefoot block to be joined with heel block

Joining of forefoot & heel blocks with tyre cord.

Filling the gap between 2 blocks with BCC to make 1

Assembling of BlocksAssembling of Blocks & ToesAssembling of Blocks & Toes

Place the foot block which is now a combination of heel block and forefoot block on top of the BTC sole surface. Place the ankle block over the heel block. Check whether alignment is correct from all directions and bolt is perpendicular to ground. The most important factor here is that the bolt has to be perpendicular to the ground. Joining of footblock and ankle block

uisng tyre cord


Fill up the gap with BCC between ankle block and heel block. Place the toes at their respective place and attach all the components of foot firmly with tyre cord strips.

Filling up gap between ankle and foot block with BCC

Joining of toes with foot block using strips of tyre cord.


Pull the tyre cord from different sides and place one after another on top of the ankle block as shown in the figure. Ensure the bolt is also encircled with the tyre cord from different directions.

Joining foot block and ankle block ‘Y’ splitting the tyre cord to be

fixed on two sides of carriage bolt.

‘Y’ splitting from ‘back’


Good wrapping of tyre cord only can ensure longer life of the foot but overuse of it will make the foot heavy. Tyre cord ties up different blocks like ankle block, heel block, forefoot block and toes like natural foot anatomy (Like Ligament and Tendons ). Close the die to ensure that build up is not too much.

Checking with the dieAll blocks tied together with tyre cord.


Cut 3cm wide strips of RCC or skin cushion compound & wrap tightly around blocks. Make sure that RCC is uniform all around and uniform pressure is applied while wrapping. Take care that no air bubbles are left while wrapping the rubber around blocks. Do not use it in excess to get better finish because that will make the foot heavy.

3 cm strip of RCC RCC wrapping around the whole foot.

Cosmeting CoverCovering with Skin Cushion CompoundCovering with Skin Cushion Compound

Wrapping around ankle

Place the foot piece in die and close the die tightly. While closing the die, tighten all nuts and bolts uniformly. This process will apply equal pressure from all around. After closing tightly, leave the die for one hour.

RCC wrapping around the whole foot ready for vulcanisation

Checking with the die.

Cosmetic CoverCovering with Skin Cushion CompoundCovering with Skin Cushion Compound

During this time rubber foot will be under pressure, which facilitates rubber to acquire inside shape of die. Open the die after one hour & inspect foot for any damage & air bubbles.

Opening the die after 1 hourClosing of the die to add pressure

Cosmetic CoverCovering with Skin Cushion CompoundCovering with Skin Cushion Compound

For adding pressure

After opening cut the extra skin with a sharp knife. If any bubbles are found, burst it with pointed screw driver or pointed edge of scissor. Fill all the cavities and uneven surface with skin cushion compound. Now Jaipur Foot is ready for vucanisation/cooking.

Unvulcanised foot after opening the die Cutting of extra RCC

rubber

Adding extra strip to fill the gap

Checking the air bubbles

Covering with Skin Cushion CompoundCovering with Skin Cushion CompoundCosmetic Cover

Jaipur Foot is vulcanised in Autoclave under 23psi pressure of steam at 125 Celsius temperature. Leave the die for 20-30 minutes inside Autoclave for curing.

Ensuring proper closure of autoclave Checking the pressure

VulcanisationVulcanisationVulcanising of Foot

For Cooling

Replace the repaired foot piece in die and close the die tightly. Place the die in Autoclave. This process of heating the rubber foot with steam is known as Vulcanisation. During vulcanisation soft and uncured raw rubber becomes ready to use & durable.

Closing the die again

Placing the die in autoclave for vulcansiation

Tightening the nuts & bolts

Closing the autoclave


In Autoclave

Remove the die from autoclave and keep it for 12 hours in a cooler place for cooling. Do not open the die before it is fully cooled as this may cause air bubbles in rubber thus destroying the look, shape and strength of foot piece. Open the die and remove the foot piece slowly. While removing, do not damage the thread of the bolt.

Vulcanised Jaipur Foot

Opening of die after vulcanisation

Tool to prevent damage of the thread


Removing the foot from the die with care

One can make Jaipur Foot with various types of attachment or bolt assembly to fit any kind of prosthetics technology. It is the most popular foot in India and it will remain so till better alternatives come but experience says it might take ages. So till then, let us go on making good quality Jaipur Foot that would help Persons who do not have a leg, to be in the society as an important active equal member.

A step forward ……

Checking whole surface and finish.


Trim extra rubber with a very sharp knife to have a better finish. While trimming make sure that the knife does not go deep because in that case it will expose black rubber underneath. Once it is trimmed Jaipur Foot is ready to be fitted with socket and socket extension to make a prosthesis.

Trimming extra rubber Finished foot after trimming

VulcanisationVulcanisation

Ready for use

Vulcanising of Foot

1. Diamond Rubber Industry Hansi, Harayana-125033India

2. M/s New Ashoka BatteriesAgra Road, Jaipur Rajasthan, India

Annexure A

Materials and equipment suppliers in IndiaVulcanising cement

Black cushion compound ( unvalcanised rubber compound MRF code 7401203), Tyre cord ( rubberised rayon/ Nylon cord CRF 70x500; MRF code 7311400/7321400, Black tread compound MRF code 7403303 & Skin compound ( unvulcanised skin colour rubber compound)

1. Madras Rubber Factory Ltd(MRF)826 TaraporetowerAnna Road, Chennai- 600032Tamil Nadu , India

2. Sundaram Industries Ltd. Rubber Factory (TVS)Post box number 6Usilampatti Road,KochadaiMadurai-625016Tamil Nadu - India

3. Asia Rubber MillRailway RoadGurgoan, Haryana- 122001, India

4. Rajasthan Rubber IndustriesF-141 IP Industrial AreaKota- 324005Rajasthan, India

Rubber Solution ( Dunlop Solution)1. Dunlop India Ltd.

57B Mirza Ghalib RoadKolkatta, West BengalIndia-700016

Microcellular Rubber1. Mahaveer Rubber Industries

48, Industrial AreaBais Godam, JaipurRajasthan- 302005, India


Preetam going through the daily chores Relaxing with a cup of tea

The dream foot for millionsThe dream foot for millions

Thank you to all who assisted us to complete this manual,especially members of Jaipur Foot Production Unit of Mobility India.

Drill Machine, Band Saw, Grinder etc.1. Machine tools & traders

NR Road, Bangalore, India

2. Polytech Mechanical IndustriesAhmedabada, GujaratIndia

3. Batlibal & Company Pvt. LtdV.B.,Gandhi Marg, FortP.O. Box -190AMumbai-400023, India

Auto Clave Machine1. Time Surgicals

Near Ajmer PuliaHathoj, Jaipur, India

2. Nat Steel Equipments Pvt. LtdMumbai, India

Aluminum Dies1. Om Engineering Works

A-12, Gayatri NagarSodala, Jaipur, India

2. S.K. Engineering Works 54- Paras Ram nagarDher ke BalajiJaipur- Rajasthan, India

For any further assistance in training and procuring tools, machinery, material, Jaipur Foot, Dies Prosthetics/Orthotics components contact:

MOBILITY INDIAST ST ND1 & 1 A CROSS J.P. NAGAR 2 PHASE

BANGALORE 560 078, INDIATEL: +91 (080) 649 2222 or 649 4444

EMAIL: Website:

[email protected]

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JAIPUR FOOT MANUAL