One embodiment relates to an orthopedic precast comprises a knitted shell portion and a knitted flexible portion. Heat or other hardening agent is used to harden the shell portion, while retaining flexibility in the flexible portion. Contemplated hardening agents include light, heat, and chemical polymerizing agents. In some embodiments the shell portion includes thermoplastic threads or yarns, which is then hardened by heating the thermoplastic sufficiently to at least partially melt, and thereby fuse together some of the threads or yarns, and then cooling to ambient temperature for enhanced rigidity. In other embodiments, the precast is contained in a bag or other airtight container, along with a self-heating composition that is triggered to release heat upon contact with oxygen. In still other embodiments, the precast includes a prepolymer of other polymerizable composition, which is polymerized by effective application of light, heat, and/or chemical agent(s) or deployed as a wearable.

An orthopedic precast comprises a knitted shell portion and a knitted flexible portion. The precast is positioned about a limb or other mold, and heat or other hardening agent is used to harden the shell portion, while retaining flexibility in the flexible portion. Contemplated hardening agents include light, heat, and chemical polymerizing agents. In some embodiments the shell portion includes threads or yarns comprising a thermoplastic, which is then hardened by heating the thermoplastic sufficiently to at least partially melt, and thereby fuse together some of the threads or yarns, and then cooling to ambient temperature. In other embodiments, the precast is contained in a bag or other airtight container, along with a self-heating composition that is triggered to release heat upon contact with oxygen. In still other embodiments, the precast includes a prepolymer of other polymerizable composition, which is polymerized by effective application of light, heat, and/or chemical agent(s).

An orthopedic precast comprises a knitted shell portion and a knitted flexible portion. The precast is positioned about a limb or other mold, and heat or other hardening agent is used to harden the shell portion, while retaining flexibility in the flexible portion. Contemplated hardening agents include light, heat, and chemical polymerizing agents. In some embodiments the shell portion includes threads or yarns comprising a thermoplastic, which is then hardened by heating the thermoplastic sufficiently to at least partially melt, and thereby fuse together some of the threads or yarns, and then cooling to ambient temperature. In other embodiments, the precast is contained in a bag or other airtight container, along with a self-heating composition that is triggered to release heat upon contact with oxygen. In still other embodiments, the precast includes a prepolymer of other polymerizable composition, which is polymerized by effective application of light, heat, and/or chemical agent(s).

The invention relates to a knit fabric for orthopedic support material. The knit fabric comprises in the weft yarn in-lay/cross direction synthetic organic microdenier yarn of no greater than 1.5 denier per filament (dpf) and synthetic organic multi-filament yarn of greater than 2.5 denier per filament (dpf). It is impregnated with a curable resin which on activation with a curing agent forms a cast supporting the patient's limb. The knit fabric according to invention exhibits the high holding capacity of the resin over time, said capacity being sufficient to prevent resin leak from a resin-coated fabric.

Method of using a shape-formable apparatus comprising fibrous material. A shape-formable apparatus can include an envelope defining a chamber, a port positioned to fluidly couple the chamber with ambience, and a fibrous material positioned in the chamber. The fibrous material can be substantially less formable when the apparatus is in the second state than when the apparatus is in the first state. The method can include providing the shape-formable apparatus in a first state; forming the apparatus into a desired shape; and reducing the pressure in the chamber to change the apparatus from the first state to a second state in which the apparatus is substantially less formable than in the first state.

This invention relates to a hybrid fabric comprising at least one structural fiber having a first melting temperature range and at least one thermo-formable fiber of having a second melting temperature range which is lower than the first melting temperature range to such an extent that the structural fiber does not melt in the second melting temperature range of the thermo-formable fiber. The hybrid fabric comprises (1) a first network comprising the structural fibers, (2) a second network comprising the thermo-formable fibers, the thermo-formable fibers comprising non-relaxed fibers made of a thermoplastic material, and (3) a plurality of openings between the fibers of the first and second network. The structural and thermo-formable fibers of respectively the first and second network interpenetrate one another and are connected to each other over at least part of the first and second network at a plurality of knot positions in the fabric where the structural and thermo-formable fibers are interwoven.