• Certification and Education
  • Specs
  • Catalog
  • Distributors
  • Socket Construction Secrets
  • Casting & Fabrication Videos
  • Configurations
  • Interchange And Compatible Parts
  • Airpuck™ Vacuum Sources
  • Proximal Socket Seals
  • FAQ
  • Coding and Reimbursement
  • Brochures/Manuals
  • Certified Fabrication Facilities
  • SmartPuck Features
  • AirPuck Features
  • Clinical Papers
  • Learning Center

Prosthetist’s Corner

Certification and Education

WEBINAR CERTIFICATION

To become certified in the the fabrication, installation and operation of any of our products via free live webinar, send a email to:

chris@5280prosthetics.com

 

ONSITE TRAINING (At Your Facility)

Become a Puck Technology & X-LIM Vacuum Socket Certified Facility Listed on our website.

Bring our team to your practice for professional clinical training.

Course fee: Contingent on number of attendees

Course Date: Call to schedule a date that works for your facility or email chris@5280prosthetics.com

Course Includes:

  • 8 ABC MCE credits
  • Fabrication Training
  • Vacuum Socket techniques
    SmartPuck, AirPuck, VaporPuck Technology / APP training
  • X-LIM Vacuum Socket System

TRAINING AT OUR FACILITY (Littleton, Colorado)

Become a Puck Technology & X-LIM Vacuum Socket Certified Facility Listed on our website.

Course fee: $95.00

Course includes:

  • 8 ABC MCE credits
  • Fabrication Training Vacuum Socket techniques
    SmartPuck, AirPuck, VaporPuck Technology / APP training
  • X-LIM Vacuum Socket System
  • Call to schedule a date that works for your facility or email chris@5280prosthetics.com

PROFESSIONAL MEETINGS

ACA Convention – Tucson, AZ,  July 23-25

The North Carolina Chapter of the Academy and the South Carolina Society of Orthotists & Prosthetists –    Charlotte, NC, October 1-3

AOPA – San Antonio, Oct 7-10

ABC accredited CEU Courses – 8 credits

Georgia Tech – June 26

Eastern Michigan University – Aug 22

Texas Scottish Rite Hospital – Sept 9

Specs

SMARTPUCK SPECS                                 

  • Weight: 194 grams
  • Height: 1.90 inches
  • Diameter: 2.5 inches
  • Fabrication: Drop In
  • Weight limit: 250 lbs
  • Min vacuum: 1 in/hg
  • Max vacuum 19 in/hg
  • Bleed rate: Set – Natural
  • Battery: Induction Charging
  • Battery life: 24 – 48 hours
  • Attachment:  Standard Euro Four Hole

AIRPUCK SPECS

  • Weight: 164 grams
  • Height: 1.90 inches
  • Diameter: 2.5 inches
  • Fabrication: drop in
  • Weight limit: 250 lbs
  • Min vacuum: 1 in/hg
  • Max vacuum 25 in/hg
  • Bleed rate: Manual
  • No Battery
  • N/A
  • Seal: Self Sealing Silicone
  • Attachment: Standard Euro Four Hole

Catalog

SmartPuck Intelligent Vacuum System             Part# SP-200

The SmartPuck comes with a Gift of an Apple iPod Touch!

Patent Pending

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AirPuck Vacuum System         Part#  AP-100

Patent Pending

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Distal Injection Tool          Part#  AP-100-DI

Patent Pending

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Lamination Tooling    AP-100MD-L

 

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ThermoPlastic Tooling          Part#  AP-100MD-T

 

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PUCK Tool Kit

PUCK Tool Kit    (For Thermoplastic Socket fabrication) 

This kit standardizes socket fabrication. Provides exact four hole and side hole placement, as well as get the distal surface perfectly paralell (critical for socket strength).

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PUCK Cutting Tool

 

PUCK Cutting Tool

Used to create an even surface with the molding dummy.

This process reduces stress to the puck body as well as reduces shear forces to bolts.

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PUCK Side Hole Jig

 

PUCK Side Hole Jig

This is used to create the side hole for the airpuck only (SmartPuck™ system does not require a side hole).

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PUCK Distal End Pad Silicone Cartridge (400ml)

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PUCK Silicone Injection Gun

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4HDIE

PUCK Four Hole Drill Guide (Interior Socket Design)

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PUCK Vacuum Lubricant

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PUCK Vented 2-part Socket Adapter Plate

 

Distributors

Our products can be purchased directly through 5280 Prosthetics LLC or though the following distributors.

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Socket Construction Secrets

Making an air tight socket has never been easier…

Smooth void or recess:

The dummy set up is critcal, make sure the entire dummy is nylon and debree free. The proximal end of the dummy is where the air seal is created. Make sure there nothing that can create an air channel up the side of the plastic in this area. The airpuck and SmartPuck™ will self seal the socket as long as the void recess is perfectly smooth.

Plastic pull:

To create a sealed socket everytime. Simply blister form socket material over the molding dummy and model. Whether the socket is thermormed or laminated all vacuum sockets require a thermoplastic inner socket to seal the system. Besure to drill an air hole down throught the model using the drill guide in the center of the molding dummy.

Trick to vari the socket wall thickness: shorten your model length to thicken the socket walls, extend the model length to thin the socket walls.

Plastic material:

We recommend using otto bock thermolin stiff plastic (or similar) for diagnostic sockets. The material is strong enough to allow the patent to wear the socket without having to worry about the socket failing (as with petg). 90% of our sockets are copoly thermoplastic pulled by a thermoformer. Plastic sockets flex (this helps to reduce shear forces on the limb), are very durable (if pulled in a uniform maner), have improved comfort and can be fabricated in a more expedient maner.

Laminations:

Always start with a petg or other plastic as the airtight foundation for your socket. Lay up the socket in the perfered maner. If you have begun to laminate with more flexibe resins and materials, consider using a more flexible inner plastic to seal the inner socket. Petg can fracture with lamination flex.

Socket fit and assessment:

Since the airpuck and SmartPuck™ are inside the socket and also serve as the connection component it is not necessary to glass wrap the socket. The prosthetist should have full view and adjustment room necessary to make heat modifications to the socket. The diagnostic socket looks clean and can truly be used as a diagnostic tool. If the socket pull is thin / inconsistent, made of petg, or if the patient is very high activity it may be necessary to glasswrap the socket.

The key to the socket strength:

The cylinder shaped void that the molding dummy creates is inherently strong. The secret to reducing shear stresses at the puck / component connection is to make sure the distal socket interior surface and exterior surface are perfectly parallel. The interior surface is always straight and smooth thanks to the molding dummy. If the socket is laminated the exterior surface will be perfectly parallel because the lamination dummy creates the entire distal surface. Thermoplastic sockets, however, require that you cut down the exterior surface to be perfectly parallel with the interior surface. This can easily be achieved with the proper tooling. We recommend pdi ssft tooling kit, it’s an investment, but you with thank us later! Not to mention this will create a standardization in how the socket is fabricated. The tooling helps to create a perfect four hole pattern and perfect side hole (airpuck only) evry time. The tools are high quality and last.

Distal end pad or transition ring:

It may be necessary to create a transition pad/ring between the molding dummy and the model. Keep the ring as smooth and as low profile as possible. The smoother the transition between the socket and the molding dummy the better. The goal of a good transition ring is to provide total contact for the residual limb as well as allow the molding dummy and puck system to be installed and removed without obstruction.

Proximal socket seal considerations:

The airpuck and SmartPuck™ systems completely seal the distal end of the socket. No leaks occur in the distal end of the socket when the puck is installed correctly. The primary consideration is how efficient the proximal seal is.

Internal socket seals are more positive and typically bleed less through out the day. However, the actual vacuum area in the socket is less.

External seals such as sleeve suspensions work great. However, do provide a weak link in a vacuum system as they can bleed vacuum especially if a high level of vacuum is being maintained or if there is a tiny hole in the sleeve.

Casting & Fabrication Videos

Casting Technique

 

Step 1: Model Prep and Alignment Videos


Step 2: Distal Transition Videos

BEFORE SOCKET PULL (PRE-FAB)

AFTER SOCKET PULL (POST-FAB)


Step 3: Socket Fabrication Videos

THERMOPLASTIC

LAMINATION

CAD


Step 4: Installation Videos

Coming Soon


Step 5: App Instruction Videos

Coming Soon

Configurations

The SmartPuck™ and airpuck can be used in multiple socket configurations.

Thermoplastic:

Trans-tibial Check Sockets And Definitive Sockets

Laminated Trans-tibial Sockets

Interior Mechanical Seal Transfemoral Or Transtibial Aura Seal, Esp Secure-ring System And Symmetry Liners

Otto Bock Pro-Seal

Ossur Seal In Liner

Two Stage Trans-tibial And Trans-femoral

Trap Door Design Trans-femoral

 

 

Interchange And Compatible Parts

The diameter of the SmartPuck™ is the industry statndard of 2.5 inches. The following components can be interchanged with the SmartPuck™ and AirPuck™ system.

The AirPuck™ and SmartPuck™ are the exact same dimension and can be interchanged with ease.

With spacers or topfill plates the following components can be used and interchanged with the 5280 puck system to allow patients to trial different suspension methods.

  • KISS
  • PDI
  • Lock
  • Lanyard
  • Side Winder
  • Vac Loc
  • Bulldog
  • American Prosthetics
  • American Prosthetics Pyramid
    Part# TI-425-BHCL

Airpuck™ Vacuum Sources

Actron Hand Pump (Part Number CP7830)

Build Your Own Electric Pump

The aipuck can be connected to any active vacuum source

  • Ottobock P3
  • Ottobock Epulse
  • Ottobock Triton Foot (vacuum)

Proximal Socket Seals

With the advent of the SmartPuck™ and AirPuck™ system clinicians and patients no longer have to worry about distal socket air leaks. The only air leaks that occur are at the proximal seal.

The AirPuck™ and SmartPuck™ are compatible with the following proximal seal systems:

  • Sealing sleeve (trans-tibial or trans-femoral)
  • pro-seal (otto bock)
  • seal-in liner (ossur)
  • aura seal (ossur)
  • secure –ring system (esp)
  • symmety liner (symmetry) – AirPuck™
  • Liner reflection methods

FAQ

Q:  Why does a internal vacuum work so much better than an external vacuum unit (basically all other vacuum products)?

A:  By having the vacuum pump, connection fittings and seal system inside of the socket there real is no where the socket can leak air.  The only place the system can leak is the proximal sealing sleeve or internal mechanical seal.  This is what makes Puck Technology work so well.

Q:  If I am doing a drop in vacuum unit, how do I achieve total contact on the distal end of the socket?

A:  There are two great ways to do this:  1)  Pull a polyethylene flexible inner socket. 2)  Use the 5280 Distal End Injection Tool, this clever tool allows you to inject a custom silicone distal end pad in the socket while the patient is actually standing in the socket.  This ensures you have total contact AND gives the patient the correct socket chamber depth (because it is done in the weight bearing position).

 

Coding and Reimbursement

AIRPUCK RECOMMENDED L CODES

(Note: A hand or electric pump must be provided in addition to the AirPuck™ as there is no active vacuum pump inside the AirPuck™, an external vacuum source is required to achieve vacuum)

  • L5781 Vacuum Pump or L5782 HD Vacuum Pump
  • L5668 Distal Pad
  • L5645 or L5651 Flexible Inner Liner (Trans-tibial / Trans-femoral)

SMARTPUCK RECOMMENDED L CODES

  • L5781 Vacuum Pump or L5782 HD Vacuum Pump
  • L5668 Distal Pad (If Utilized)
  • L5645 or L5651 Flexible Inner Liner (Trans-tibial / Trans-femoral)
  • L5999 Induction wireless charging system with electromagnetic field energy transfer microprocessor, corrosion proof and connectionless charge base.
  • L5999  Mobile Control Strategy & Feature selection Application with one button access to 24 different vacuum suspension levels, wireless adaptability, bluetooth, compatible with Apple IOS

 Physician Documentation Checklists:

Certified Fabrication Facilities

5280 puck tech logo_final

Contact:

Toll Free: 1-888-543-PUCK  Email: Clint@5280prosthetics.com

Address:1501 West Campus Drive Suite J  Littleton, CO 80120

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Contact:      

Toll Free:  1.800.FABTECH

Direct: 425.349.9557         Fax: 425.349.9559

Address:
3304 Hill Avenue  Everett, WA 98201

 

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Contact: 1.800.408.3598

Fax: 1.800.408.3596

Address:

527 Park Lane, Suite 200
Waterloo, IA 50702

SmartPuck Features

Negative Pressure Tank side-viewThe SmartPuck™ housing serves as a negative pressure tank. This extra space serves as an air reservoir, which reduces the run time of the vacuum pump and the drain on the battery. Less run time makes the pump less noticeable and more socially acceptable.

 

 

 

Structural Attachment bottom-viewThe bottom portion of the SmartPuck™ housing serves as a structural attachment point to affix distal prosthetic components below the socket. This reduces the build height of the prosthesis and allows for a better selection of prosthetic knee units as well as prosthetic feet.

 

 

 

 

 

side-viewAdjustable Socket Sealing System

The SmartPuck™ utilizes a flexible gasket that is positioned between the housing body and the top-sealing disc. The sealing disc can be tightened to the housing body causing expansion of the gasket. The gasket material flows toward the socket wall tightening the air seal. This feature helps prevent air leaks from cold flow and plastic creep.

 

 

 

Low Build Height side-viewEntire build height of the SmartPuck™ system is 1.75 inches. No special adaptors or attachment devices are necessary. Space between the socket and knee unit or foot is critical. The SmartPuck™ allows for patients and prosthetist to choose from the widest selection of high end prosthetic components.

 

 

 

Light Weight The SmartPuck™ is the lightest commercially available vacuum system available on the market. The entire unit weighs 170g! The SmartPuck™ also serves as the structural attachment… no additional adaptors or weight is required to connect he socket to the external components.

 

 

 

Low Noise Emmision noise-reductionThe location of the Smart Puck inside the Socket and under the cosmetic cover/skin makes the device very quiet. The decibel rating is nominal, making the system more socially acceptable.

 

 

 

 

 

 

 

 

 

Proximal Seal Placement bottom-viewThe placement of the seal is above where the pushpin of a lock typically sits. The seal location allows for holes to be drilled in the socket sidewall. The benefit of this is that a prosthetist and patient could try a vacuum, pin or lanyard all in the same socket. Being able to actually try different suspension methods is often beneficial for patients when deciding between several suspension methods.

 

 

 

Modular Design side-viewThe SmartPuck™ is a modular component that can be inserted or replaced with ease. The Puck may be interchanged with various other components if the patient does not like elevated vacuum as their suspension. Little or no special fabrication is required to utilize the device. Works in test sockets, laminated sockets and thermoformed sockets.

 

 

 

Protection protectionSince the entire device is located inside the socket the SmartPuck™ is protected from water, dust and impact.

 

 

 

 

 

 

 

 

 

Self Contained self-containedNo wires, hoses, charge ports, communication links or valves are located outside the socket. The device makes installing a cosmetic cover easy. No holes are required in the prosthetic cosmetic skin for any reason.

 

 

 

 

 

 

 

 

Bluetooth The SmartPuck™ system uses state of the art Bluetooth technology to communicate with Apple Products. Google, BlackBerry compatibility available soon.

 

 

 

Magnetic On/Off Switch side-viewThe SmartPuck™ can be operated with or without a smart phone. A magnetic switch can be used to turn the device on or off. The on/off mode can be set to a predetermined level or on an automatic setting.

 

 

 

 

 

Internal Induction Charger chargerThe SmartPuck™ system comes with a custom designed induction charge system and specially designed charge cord. The induction charger is located just under the seal plate. The charger connects with the induction charge port by magnetic screws located on the topside of the seal plate. The charge cord is simply dangled inside the socket when the patient removes the prosthesis. The magnets in the charge cord connect with the seal plate and automatically align the charger. The induction charger is fluid and corrosion free.

 

 

 

 

Internal Microprocessor protectionThe SmartPuck™ is designed with an advanced microprocessor system. The added computing power packs more punch to the functional capacity of the system.

AirPuck Features

Negative Pressure Tank airpuck-side-viewThe AirPuck™ is essentially a hollow “Tank” that acts as a vacuum reservoir. Once the prosthesis is applied, the air inside the socket is evacuated by means of an external vacuum pump. The AirPuck™ Systems allows amputees to experience the benefits of vacuum all day long.

 

 

 

 

 

Lock Valve or Free Flow Barb ap-bottom-viewThe AirPuck™ utilizes a “leak Proof” valve called a LOCK VALVE. The valve can be opened to evacuate air out of the socket and then easily closed to seal in the vacuum pressure. The Valve Housing has neatly concealed vacuum barb that can be connected to any vacuum source. Most users evacuate the air once in the morning using a hand held electric or manual vacuum pump. The AirPuck™ can maintain vacuum suspension all day long. The valve can be modified to be a free flow valve for users who wish to permanently connect the AirPuck™ to a vacuum source such as an Otto Bock P3 Harmony Pump.

 

Interchangeable With SmartPuck™ interchangeThe AirPuck™ and the SmartPuck™ are of equal dimensions. Each can be interchanged with the other. The AirPuck™ does require a side hole. However, due to the seal placement, the side hole does not affect the socket seal.

 

 

 

 

 

Low Build Height airpuck-side-viewEntire build height of the AirPuck™ system is 1.75 inches. No special adaptors or attachment devices are necessary. Space between the socket and knee unit or foot is critical. The AirPuck™ allows for patients and prosthetist to choose from the widest selection of high-end prosthetic components and feet which require more space.

 

 

 

 

 

Light Weight ap-bottom-viewThe AirPuck™ is the lightest commercially available vacuum system available on the market. The entire unit weighs 174g! The AirPuck™ also serves as the structural attachment… no additional adaptors are required to connect he socket to the external components. The valve mechanism and socket seal are built into the Puck body, reducing the need for extra components and weight.

 

 

 

No Noise Emissions ap-no-noiseThe AirPuck™ contains no electric or mechanical pumps that produce noise. Once the air inside the socket has been removed by means of an external pump, the vacuum is maintained all day with no noise emissions.

 

 

 

 

 

 

 

 

Proximal Seal Placement ap-no-noiseThe placement of the seal is above where the pushpin of a lock typically sits. The seal location allows for holes to be drilled in the socket sidewall. The benefit of this is that a prosthetist and patient could try a vacuum, pin or lanyard all in the same socket. Being able to actually try different suspension methods is often beneficial for patients when deciding between several suspension methods.

 

 

 

 

 

 

Modular Design airpuck-side-viewThe AirPuck™ is a modular component that can be inserted or replaced with ease. The Puck may be interchanged with various other components if the patient does not like elevated vacuum as their suspension. Little or no special fabrication is required to utilize the device. Works in test sockets, laminated sockets and thermoformed sockets.

 

 

 

 

 

 

Protection ap-no-noiseSince the entire device is located inside the socket the AirPuck™ is protected from water, dust and impact. There are no hoses, wires, charge ports or vacuum barbs that can be damaged during everyday use.

 

 

 

 

 

 

 

 

Self Contained ap-self-containedNo wires, hoses, charge ports, communication links or valves are located outside the socket. The device makes installing a cosmetic cover easy. No holes are required in the prosthetic cosmetic skin for any reason.

 

 

 

 

 

 

 

 

Cosmetic Friendly ap-cosmeticThe AirPuck™ system makes cosmetic cover installation easy. (Access to the valve is required on the AirPuck™.)

 

 

 

 

 

 

 

 

Durability airpuck-side-viewThe AirPuck™ is impervious to water, dust, mud, impacts and static electricity. The AirPuck™ is the most durable vacuum system on the market today.

 

 

 

 

 

 

Compatible Vacuum Sources ap-compatible-vacuumThe air inside the AirPuck™ is typically evacuated by means of an electric vacuum pump or mechanical hand pump. Once the air is removed the pump can be disconnected. The valve system can be modified to connect to an active vacuum pump such as an Otto Bock P3 Harmony Pump

 

 

 

 

 

 

 

Structural Attachment ap-structural-attachmentThe bottom portion of the AirPuck™ housing serves as a structural attachment point to affix distal prosthetic components below the socket. This reduces the build height of the prosthesis and allows for a better selection of prosthetic knee units as well as prosthetic feet.

Clinical Papers

Below are links to several clinical papers going into further detail on the benefits of elevated vacuum:

  1. Residual limb wounds or ulcers heal in transtibial amputees using an active suction socket system. A randomized controlled study. http://www.ncbi.nlm.nih.gov/pubmed/2264124
  2. Outcomes Study of Transtibial Amputees Using Elevated Vacuum Suspension in Comparison With Pin Suspension. http://www.oandp.org/jpo/library/2011_02_078.as
  3. Elevated Vacuum Suspension Influence on Lower Limb Amputee’s Residual Limb Volume at Different Vacuum Pressure Settings. http://www.oandp.org/jpo/library/2010_04_252.asp
  4. Using Elevated Vacuum to Improve Functional Outcomes: A Case Report. http://www.oandp.org/jpo/library/2011_04_184.asp
  5. Vacuum Suspensionand its Effects on the Limb. http://www.ottobock.com/cps/rde/xbcr/ob_us_en/im_646d277_gb_vacuum_suspension.pdf