Curable, conformable composite precursors, conformable core structures, resulting products and methods

Abstract

The application discloses a conformable support structure for use in fiber composite precursor; a resin impregnated conformable fiber composite precursor, which may surround the support structure, for being manually manipulated and plastically deformed into a desired shape before being cured into a final product having the desired shape; the corresponding final product, which may be an orthosis or other product; and methods of making the final product or orthosis. The support structure is typically plastically deformable by hand to form the desired shape, may be substantially planar and may have various voids to promote controlled plastic deformation of the frame in one or more desired directions. The core may comprise a wire or tube and may include packing or filler material. The precursor includes a fiber layer impregnated with a thermoset resin and includes a compressor around the fiber layer. The fiber layer is supported internally or externally by the conformable support member. The precursor may be custom fitted to match the shape of an object and then thermally cured into a strong rigid product. The cured precursor can then be used to make a custom finished product.