Liner system and liner for prosthetics and method for using and making

A method for cushioning a residual limb in a prosthetic socket comprising:

• providing a compressible foam insert, said insert comprising a substantially cylindrical hollow interior defined by an interior insert surface and an opening, said opening and said hollow interior configured to accept a substantial portion of a residual limb;
• inserting a distal end of said residual limb through said opening and into said hollow interior such that said limb substantially fills said hollow interior;
• providing a socket of a prosthetic limb, said socket comprising a substantially concave interior and opening wherein said opening and said concave interior are configured to accept a substantial portion of said compressible foam insert, wherein said concave interior is defined by a concave laminar pocket;
• and
• inserting said distal end of said residual limb with said foam insert into said concave interior of said socket of said prosthetic limb, such that said foam insert with said residual limb substantially fills said concave interior.

A method for forming a prosthetic socket liner comprising:

• forming a first negative casting of a residual limb;
• forming a first model of said residual limb from said first negative casting of said residual limb, said first model having an exterior surface, wherein said exterior surface substantially conforms to an exterior surface of said residual limb;
• forming a first liner from said first model of said residual limb, said first liner having an opening and a first hollow interior substantially conforming to an exterior surface of said first model of said residual limb, wherein said first liner comprises a first material;
• donning said first liner over said residual limb, wherein said residual limb substantially fills said first hollow interior;
• forming a second negative casting, wherein said second negative casting is a casting of said first liner while said first liner is donned over said residual limb;
• forming a second model of said second negative casting, said second model having an exterior surface substantially conforming to an exterior surface of said second negative casting;
• forming a second liner from said second model, said second liner having an opening, an exterior defined by an exterior surface, and a second hollow interior defined by a second interior surface, said second interior surface substantially conforming to an exterior surface of said second model, wherein said second liner comprises a second material;
• and
• adhering cover layers to said second interior surface and said second exterior outside surface of said second liner.