Mould Room

It usually takes two visits to the mould room to make a shell. Each visit takes between half an hour and an hour. At the first visit you are asked to lie on a hard table and an impression is taken of the area to be treated. This involves applying some wet plaster of Paris bandages to the area. These are built up in layers and form a plaster impression of the surface of the part of your body that we want to treat. As the plaster hardens there is a chemical reaction in the bandages and they feel slightly warm. When the mould room technician is satisfied that the impression is accurate, then that's it for the day. You will be given an appointment to return to the mould room in a few days time for a fitting. It's quite like having a suit made - first the measurements, then the fitting and adjustments.

While you are away, the mould room technician makes the main part of the shell. From the impression they make a replica of the part of you to be treated. This is then used as a mould over which clear plastic (about 2mm thick) is formed in a powerful vacuum. The result is a clear plastic shell which fits you snugly.

When you return for your fitting adjustments are made to the shell to make sure it is snug but comfortable. The plastic struts that fit it to the treatment table are added, again ensuring a comfortable fit. This all takes another half hour or so. Once the technician, and, more importantly, you are happy with the shell, then it is time to move on to the next stage in the planning process: usually a visit to the simulator.