MalleoLoc® Stabilizing Ankle Brace

We encourage you to check the fit of the brace on the wearer’s foot and ankle. If the brace is not flush against the foot, the thermoplastic material is easily reshaped by using a heat gun.

Here is a quick checklist to determine if the brace needs to be reshaped.

Once the brace is fastened to the wearer’s foot:
  • Is there a gap between the edge of the foot and the brace itself?
  • Is there any space between the lower ankle and the brace?
  • Does the wearer notice any uncomfortable pressure points?

There are two critical points where most of the heating and adaptation must be done; both are found at the lower outside part of the shell:

1) Outer shell near the plastic strap buckle

2) Outer shell at the bottom of the foot

Heating and Adaptation

WITH THE BRACE OFF THE FOOT:

Peel back the inner foam liner to prevent damage to it from the heat treatment, but you do not have to remove it completely (around two-thirds peeled back). It is easier to remove the inner foam liner when it is cold, you can achieve this by putting it in the freezer for a few minutes. 

The glue in the inner liner is heat-sensitive.  This means that if the plastic shell is heated on the exterior with a heat gun without peeling back the inner liner, then the glue will harden and it is very difficult to remove afterwards.

However, this heat-sensitive glue will help the liner to adhere back to the shell by the body’s own temperature while wearing the brace.

Once the inner foam liner is pulled back, using a professional heat gun and heat protective gloves (leather gloves), carefully heat the plastic shell (around 400°F) in the necessary area(s) until the plastic has a glossy shine.

Mold plastic to its required shape and let cool. You can use a ball hammer to create a smoother, more rounded edge to the molded area if needed. Put the brace on the foot and form the brace around the ankle.