I am heading back to school to get my master’s in prosthetics and have been shadowing at a prosthetic clinic in preparation for that. When I got my laser, one of the prosthetists and I joined forces to create designer shells for prosthetic legs to make them look stylish while protecting the hardware. This is the first prototype.
First, I designed the piece and cut it out flat. Unfortunately I had a small issue during pass-through which caused about a 1/2 inch gap in the design.
Next, we made a plaster cast of my shin to use as a forming mold.
Then we heated the plastic plate in the oven and vacuum sealed it to the mold. After it was molded and cooled, I painted the surface with auto paint using a small roller that was only slightly damp with paint. In the future, I will paint the piece while it is still flat because once we formed it to the final shape, the engraved spots opened up slightly making it more difficult to avoid getting paint in the design.
Here is the final result: