Click Medical RevoSurface User manual

1
Advisories
Must be installed by a licensed professional.
Overtightening could compromise circulation.
Lace will wear:
• Routinely check for wear or damage.
• Look for broken fibers around areas of high wear.
• Replace lace if a significant amount of fibers are broken.
• Proactively replace lace every 6 months.
• Keep lace away from open flame and sharp edges.
Weight limit: 300lbs/135kg
See instructions in other languages: clickmedical.co/instructions
RevoSurface®Tool Kit Contents:
Click Reel
Surface Guide +
Attachment Screw x 10
Metal Lace
Feeder
RS-100-07-01
Tool Kit with Click
®
Reel
Surface Collar
2.0m
HC Lace
B
A
C
Torx Head
Screw x 4
Phillips Head
Screw x 4
Surface Shim
Releasing Tab
x 5
For more resources visit:
clickmedical.co/knowledge-base
Plastic Lace
Feeder x 3
1.8m
Lamination Tube
Reel Tool
GUARANTEE
The Click Reel is guaranteed to last the life of the device
into which it is originally installed. Registration of the Click
Reel is required at the time of original device delivery. To
register: clickmedical.co/contact-us/cr-registration/
WARRANTY
For warranty information on all of Click Medical’s
products: clickmedical.co/terms/#warranty
U.S. Customers:
Contact [e-mail]
Tel: [phone]
International Customers:
Please contact your local distributor.
Click Medical products are patent protected.
For full list see www.clickmedical.co/patents

2
Additional Designs: To learn more about designing adjustable RevoSurface devices, enroll in ClickAcademy.co
Select the Application
Thermoplastic
Use these instructions if you are building a
thermoplastic diagnostic prosthesis
3D Print
Orthotics Modifying an
Existing Device
Use these instructions if you are building an
orthosiswith adjustability Use these instructions if you are adding
adjustability to an existing device
Option 1:
System wrapped in fiberglass for
higher precision and durability or
extended use
Option 2:
System fastened with
externally mounted hardware
to quickly build and assess an
adjustable design
Go to Page 7
Go to Page 7 Go to Page 7
Go to Page 3
Go to Page 13
Use these instructions if you are
building a 3D printed device

3
Determine Adjustable Design Type:
Additional Designs: To learn more about designing adjustable RevoFit devices, enroll in ClickAcademy.co
Panel Gap Hinge
RevoSurface Thermoplastic Diagnostic Wrapped in Fiberglass:
Thermoplastic
Use these instructions if you are building a
thermoplastic diagnostic prosthesis
System wrapped in fiberglass for higher
precision and durability or extended use
Determine location of Click Reel:
a. Discuss with the patient
where they would like the
reel. Consider range of
motion and accessibility.
For Panel and Hinge designs:
1. Insert pads of approximate size and
thickness into the device (one at a time)
and don the device onto the patient.
2. Get feedback from the patient about fit.
3. Adjust pad size, position, and
thickness as needed.
4. Mark final pad location, size and
thickness on the device.
For Gap designs:
1. Determine the gap size and location.
2. Mark on device.
Remove device from model and
attach necessary hardware to test
on the patient.
a. Verify volume and fit.
Pull insert
material over
mold.
Pull plastic. Determine ideal adjustment
areas
Detailed Fabrication Instructions:
Fabrication Overview:
1. Determine adjustable design
type: Panel, Gap, Hinge.
2. Determine areas of adjustment
and location of Click Reel.
3. Pull flexible insert material over mold.
4. Pull plastic over insert.
5. Draw areas of adjustment and location
of Click Reel on device.
6. Attach RevoSurface components to device.
7. Wrap all parts of the system in cast tape.
8. Cut trim lines and areas of adjustment.
9. Sand and finish edges.
10. Apply pad material.
11. Lace device.
12. Install Click Reel and test for function.
13. Deliver to patient and optimize fit.
For material suggestions and guidelines, please refer
to the Material Data Sheet:clickmedical.co/mds

4
For parallel lace path:
Use blue ports B and C
Detailed Fabrication Instructions:
Take photo of trim
lines and areas of
adjustment for
future reference.
Sand surface and wrap entire
system with cast tape.
Hint: Immediately wrap with
cling wrap to ensure a tight
bond and smooth finish.
Re-draw trim lines and
areas of adjustment.
Use photo from Step 8
for reference.
Cut trim lines.
Use small end of
segmented cast saw blade
for tight turns.
PANEL DESIGN RULE:
• ¼ rule = length of panel ÷ 4. Tube must
be ¼ distance from top/bottom edges.
• Tubes must cross panel
parallel to each other.
• Tube must cross panel at a
perpendicular angle to edge.
• Tube must extend 1cm on the
frame before turning.
GAP DESIGN RULE:
• Tubes must cross gap parallel
with each other.
• Tube must cross gap at a
perpendicular angle to edge.
• Tube must extend straight 1cm
on the frame before turning.
HINGE DESIGN RULE
• Use ¼ rule to determine where
to route closure points.
• Tube must extend 1cm on the
frame before turning.
• Hinge must be at a different
level (in the transverse plane)
than closure points.
Align tube ports with lace path and bond
or screw Surface Collar to device.
For opposite lace path:
Use yellow ports A and C
Glue tube to device frame.
a. Cut tube at angle and
insert 2cm into collar.
b. Glue along designated
path with dots of super
glue about every 2cm.
–DO NOT KINK THE TUBE–
If the tube kinks, you must
replace with a new piece.
c. Cut the other end of the tube to
length and insert 2cm into collar.
A
B
C
A
B
C
A
B
C
+ 1cm
+ 1cm
2cm
+1cm
Hinge Base
Draw lace routing onto socket:
Prepare collar:
a. Cut out fiberglass material
covering the collar.
b. Trim tube ends and
clear debris.
Lace device.
Start at the collar and use
the lace feeder to pull lace
through the device.
Feeder
Lace
Add pad material
to panels or hinge
designs.
Finish edges of frame and/or panels:
a. Sand edges.
b. Clear tube ends of debris.
c. Buff edges smooth with 1000 grit sandpaper.
For more information in
pad optimization, enroll
in Click Academy.
Flat or Convex Pad Skive Edges
15
16
Pad Shape:
Flat or slightly
convex shape
which allows
for better
application of
pressure.

5
Detailed Fabrication Instructions (continued):
Step 3
Attach lace to the Click Reel:
Step 1
Step 4
Step 2
Lace the reel using the
plastic lace feeder.
Pro Tip:
Gently pull the lace through
the cavity to avoid breaking
the plastic lace feeder.
Tie a double overhand knot
and trim tail to ~5mm and
lightly burn the end of the tail.
Relace the device.
Attach each lace to its
corresponding lace
port on the reel - A,
B, or C.
Step 5 Step 6 Step 7
2
Remove both red lock
plugs to engage the
Shift®feature of the reel.
a. b. c.
Pro Tip: Keep the red lock
plugs for future use or leave
in place to keep reel locked in
Power Mode.
Ensure that the reel is ready for
lacing. Both lock plugs should be
in place. The green marks on the
spool should align with the green
marks on the washer. If necessary,
turn dial to align green marks. Lock Plug
Lace Port C
Lace Port A
Lock Plug
Adjust alignment
by turning dial
Pull lace to seat knot in
the far lace pocket, on the
opposite side of the green
marker.
Completely push knot
into the cavity with a #1
flathead screwdriver:
17
2. Press the reel firmly into the collar (you
should hear a “CLICK” when secure).
CLICK!
Test function.
Cycle the system 3 times before delivering to verify proper function.
Important.
As a final step of fabrication, attach the patient Instructions For Use hangtag on dial.
19
20
Green
Marker
1. Insert the foot of the reel into the void in the
bottom of the collar opposite of the metal insert.
Pull open lace end to remove
loose lace from device.
Repeat Step 3 to feed open lace
end through reel.
Measure out ~10cm of lace.
Repeat Step 4 to tie double
overhand knot, trim and seat it.
Install the Click Reel:
18

6
How to use the Click Reel
Turn reel clockwise to
quickly take up lace.
Micro-adjust by turning
forward or backward.
To fully release, unwind
counterclockwise until
“clicking” stops.
Reel will automatically shift
to high power mode as it
tightens.
1 2 3 4
See clickmedical.co/instructions for detailed video instructions for replacing/re-lacing a reel.
To remove the Click Reel:
a. Locate the metal insert.
b. Insert a small #1 flathead screwdriver
between the metal insert and the reel body.
c. Gently pry the reel upwards.
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Metal Insert
Pro Tip: If you prefer the reel to operate
ONLY in Power Mode for constant
micro-adjustment, replace the lock plug
to “disable” the Shift function.
Fast Wind or Full Release
Mode = Silent (Smooth)
Power Mode =
“Clicking” (Tactile)
Pull Out
Push In
Teach your patients to care for and
maintain their RevoSurface®system:
This product is waterproof and
submersible. Rinse with fresh
water after use in saltwater,
sand, or mud.
✔
✔
✔
Inspect lace:
Check for wear or damage routinely
Replace at any sign of wear
Replace lace every 6 months
Regularly inspect your RevoSurface system.
Click Medical, LLC, 1205 Hilltop Parkway, W101
Steamboat Springs, CO 80487, USA [phone]
MDSS GmbH, Schiffgraben 41
30175 Hannover, Germany
CH
UK
MDSS CH GmbH, Laurenzenvorstadt 61
5000 Aarau, Switzerland
MDSS-UK RP LIMITED, 6 Wilmslow Road
Rusholme, M14 5TP Manchester
United Kingdom

7
Additional Designs: To learn more about designing adjustable RevoSurface devices, enroll in ClickAcademy.co
Thermoplastic
Use these instructions if you are building a
thermoplastic diagnostic prosthesis system
fastened with externally mounted hardware to
quickly build and assess an adjustable design
Orthotics
Use these instructions if you are building an
orthosiswith adjustability
Modifying an
Existing Device
Use these instructions if you are adding
adjustability to an existing device
RevoSurface Thermoplastic Externally Mounted, Orthotic Applications, Modified Device:
Fabrication Overview:
1. Determine adjustable design
type: Strap or Lacer.
2. Determine areas of adjustment
and location of Click Reel.
3. Determine likely lace guide
placements and mark their
location on the device.
4. Attach RevoSurface
components to device.
5. Lace device.
6. Install Click Reel and test for function.
7. Deliver to patient and optimize fit.
For material suggestions and guidelines, please refer
to the Material Data Sheet:clickmedical.co/mds

8
Additional Designs: To learn more about designing adjustable RevoSurface®devices, enroll in ClickAcademy.co
Pick a Design:
Strap Lacer
There are 3 strap configurations to choose from: There are 2 lacer configurations to choose from:
Fixed Lacer
For easily slipping on/off the body.
Releasing Lacer
For fully opening a device.
Simple Straps
For volume adjustments and simple don/doff.
Dynamic Straps
For fitting conical shapes or closing a larger device.
Releasing Straps
For fully opening.
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Dynamic strap can also be made with releasing guides to fully open.
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2 Fixed Guides: 2 Releasing Guides
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RevoSurface Thermoplastic Externally Mounted, Modified Device, Orthotic Applications cont:

9
Single Guide
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Too Narrow: <25 mm
Planning the Configuration:
Next, determine where you want to place the Click Reel:
a. Make sure it is in line with your likely lace path.
b. Ensure that the reel will be easily accessible by the patient.
c. Place the Click Reel so it will not protrude
and catch on clothing or edges.
Optimize the design:
a. Determine likely lace guide placements and mark their location on the device.
b. Optimize the lace angles.
c. Pair guides where possible to span larger areas.
For all designs, first determine the trim lines of
the device and sketch on device.
For the Dynamic Strap:
Place the middle guide close to the
reel to create optimal lace angles.
Single guides create closure over a smaller area. Paired guides span larger distances.
Place guides such that the lace angles are as minimal as
possible to create optimum closure force.
For the Simple Strap:
Parallel laces are best.
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Just Right: 25-50 mm
Plan your configuration well before starting to mount components!
It will save you time later.
!
Incorrect
Correct
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Greater
than 45°
Less
than 45°
Too Narrow: < 25 mm
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>25mm Paired Guides
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10
c. Arrange the top cap into the Fixed or Releasing position.
d. Attach with included hardware or rivet (not included).
Fabricating the Device:
Mount from the inside of device
with the Phillips head screws.
Mount from the outside of the device,
using Torx head screws.
Note: Make sure screw heads don’t
interfere with reel installation.
Mount the Surface Collar:
OR
Orient the pointed end
towards the direction
of the force.
Mount the lace guides:
a. Drill 5 mm holes into device at
desired guide locations.
b. Orient the guides.
Lace the device.
Start at the collar and lace through guides.
PROPER fixed guide lacing:
A
C
Lace is locked
behind keeper.
Lace is pulling
directly on keeper.
IMPROPER fixed guide lacing:
Feed lace through Snap handle onto the lace
OR
Add releasing handles to the lace (if configuring releasing guides).
Then slide the handle onto each releasing guide base.
For releasing guides, simply wrap lace around guide until
you install the releasing handle.
a. Determine ideal placement.
b. Grind a small flat area or
apply the Surface Shim.
c. Mark and drill the necessary holes,
using a 2mm drill bit for Phillips
head screws and a 1mm drill bit for
Torx head screws.
d. Attach with the included hardware.
Note:
• If running laces in parallel, use
lace ports Band C.
• If running laces opposite, use
lace ports Aand C.
B
A
C
B
Fixed Releasing
top cap
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11
Pull lace to seat knot in
the far lace pocket, on the
opposite side of the green
marker.
Completely push knot
into the cavity with a #1
flathead screwdriver:
Remove both red lock
plugs to engage the Shift
feature of the reel.
a. b. c.
Pro Tip: Keep the red lock
plugs for future use or leave
in place to keep reel locked in
Power Mode.
Attach lace to the Click Reel.
Step 1
2. Press the reel firmly into the collar (you
should hear a “CLICK” when secure).
CLICK!
Step 3
Step 5 Step 6
Step 4
Step 7
Relace the device.
Attach each lace to its
corresponding lace
port on the reel - A,
B, or C.
Step 2
Ensure that the reel is ready for
lacing. Both lock plugs should be
in place. The green marks on the
spool should align with the green
marks on the washer. If necessary,
turn dial to align green marks. Lock Plug
Lace Port C
Lace Port A
Lock Plug
Adjust alignment
by turning dial
Lace the reel using the
plastic lace feeder.
Pro Tip:
Gently pull the lace through
the cavity to avoid breaking
the plastic lace feeder
Tie a double overhand knot
and trim tail to ~5mm and
lightly burn the end of the tail.
7
Green
Marker
Install the Click Reel.
Pull the free lace end to remove
loose lace from device.
Repeat Step 3 to feed the free
lace end through reel.
Measure out ~20cm of lace.
Repeat Step 4 to tie overhand
knot, trim, burn and seat it.
1. Insert the foot of the reel into the void in the
bottom of the collar opposite of the metal insert.
Test function.
Cycle the system 3 times before delivering to verify proper function.
Important.
As a final step of fabrication, attach the patient Instructions For Use hangtag on dial.
5

12
How to use the Click Reel
Turn reel clockwise to
quickly take up lace.
Micro-adjust by turning
forward or backward.
To fully release, unwind
counterclockwise until
“clicking” stops.
Reel will automatically shift
to high power mode as it
tightens.
See clickmedical.co/instructions for detailed instructions for replacing/re-lacing a reel.
To remove the Click Reel:
a. Locate the metal insert.
b. Insert a small #1 flathead screwdriver
between the metal insert and the reel body.
c. Gently pry the reel upwards.
Metal Insert
Pull Out
Push In
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Teach your patients how to release and reconnect the releasing guides:
Release the Lace. Reconnect the Lace.
At delivery of device with patient present, scan Instructions For Use
Hangtag. Please review with your patient how to use the Click Reel
and to care for and maintain their RevoSurface system.
This product is waterproof and
submersible. Rinse with fresh
water after use in saltwater,
sand, or mud.
✔
✔
✔
Inspect lace:
Check for wear or damage routinely
Replace at any sign of wear
Replace lace every 6 months
Regularly inspect your RevoSurface system.
Fast Wind or Full Release
Mode = Silent (Smooth)
Power Mode =
“Clicking” (Tactile)
Pro Tip: If you prefer the reel to operate
ONLY in Power Mode for constant
micro-adjustment, replace the lock plug
to “disable” the Shift function.

13
Adding Adjustability to your 3D Printed Device
3D Print
Use these instructions if you are
building a 3D printed device
Fabrication Overview:
1. Pick a Panel, Gap or Hinge design.
2. Locate areas of desired adjustment
and placement of reel.
3. Download the reel mounting
geometry from Click Academy and
then integrate into the CAD model.
4. Integrate the lace paths or locations of
Surface Guides into the CAD model.
5. Print device.
6. Apply the RevoSurface components.
7. Test device for function.
For material suggestions and guidelines, please refer
to the Material Data Sheet:clickmedical.co/mds
Determine Adjustable Design Type:
Additional Designs: To learn more about designing adjustable RevoSurface devices, enroll in ClickAcademy.co
Panel Gap Hinge
PANEL DESIGN RULE:
• ¼ rule = length of panel ÷ 4. Tube must be
¼ distance from top/bottom edges.
• Tubes must cross panel parallel to each other.
• Tube must cross panel at a
perpendicular angle to edge.
• Tube must extend 1cm on the
frame before turning.
GAP DESIGN RULE:
• Tubes must cross gap parallel with each other.
• Tube must cross gap at a
perpendicular angle to edge.
• Tube must extend straight 1cm
on the frame before turning.
HINGE DESIGN RULE
• Use ¼ rule to determine where
to route closure points.
• Tube must extend 1cm on the
frame before turning.
• Hinge must be at a different level (in the
transverse plane) than closure points.
+ 1cm
+ 1cm
+1cm
Hinge Base
Draw lace routing onto socket:

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1
Integrating the Reel Mounting Geometry:
Download the dummy file for
the Reel mounting geometry. To
access this file, please enroll or
login to Click Academy. The file
can be found in the RevoSurface
Build It course.
Integrate the reel mounting
geometry into the model of
your device.
Rotate the geometry to align
the lace exits with the lace path.
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Creating Lace Path with Surface Guides:
Step 2
OPTION 1 Placing and Installing Surface Guides:
Step 1
Step 3
Mark the location of each Surface Guide screw hole on the device
Drill 3mm holes to accept the Surface Guides
After printing, identify the lace path
and surface guide locations by using
these guidelines:
4
Pair Lace Guides to create lace paths
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Paired guides span larger distances.
>25mm Paired Guides
Why use Surface Guides?
1. They are easy to place after printing.
2. They can simplify the 3D design process
3. They allow for lace path optimization after printing

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Creating Integrated Lace Path Geometry:
Step 3
OPTION 2 Creating Lace Channels:
Step 1
Step 4
Step 2
If you enclose the lace path in the middle of the lace path for printing support or
durability, keep the enclosed areas relatively short, less than 3cm.
Create open lace paths along the device to allow for printing medium to be cleaned
out of lace paths.
Create tubing channels with an inner diameter of 3.2mm so that the tubing can be
inserted into the device.
The tubing is required as it protects the lace and significantly reduces lace friction.
4
3.2mm
At the end of each open lace path, close off the entire 360-degree path for
~5mm to fully capture the tube.
This prevents deformation of the tubing during device use.
Step 5
Ensure that lace tracks will be well aligned once the device is
tightened. This will greatly increase lace life in the device.
Why integrate the lace path?
Creating 3D printed lace paths have the advantage of streamilined integration and a lower profile.
However, this technique is more complicated, so we suggest using this method only after you have
gained experience creating and printing adjustable designs.
<3cm
5mm
Poor
Alignment Good
Alignment

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c. Arrange the top cap into the Fixed or Releasing position.
d. Attach with included hardware or rivet (not included).
Fabricating the Device:
Mount from the inside of device
with the Phillips head screws.
Mount from the outside of the device,
using Torx head screws.
Note: Make sure screw heads don’t
interfere with reel installation.
Mount the Surface Collar:
OR
Orient the pointed end
towards the direction
of the force.
Mount the lace guides:
a. Drill 5mm holes into device at
desired guide locations.
b. Orient the guides.
Lace the device.
Start at the collar and lace through guides.
PROPER fixed guide lacing:
A
C
Lace is locked
behind keeper.
Lace is pulling
directly on keeper.
IMPROPER fixed guide lacing:
Feed lace through Snap handle onto the lace
OR
Add releasing handles to the lace (if configuring releasing guides).
Then slide the handle onto each releasing guide base.
For releasing guides, simply wrap lace around guide until
you install the releasing handle.
a. Determine ideal placement.
b. Grind a small flat area or
apply the Surface Shim.
c. Mark and drill the necessary holes,
using a 2mm drill bit for Phillips head
screws and a 1mm drill bit for Torx
head screws.
d. Attach with the included hardware.
Note:
• If running laces in parallel,
use lace ports Band C.
• If running laces opposite,
use lace ports Aand C.
B
A
C
B
Fixed Releasing
top cap
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5
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7

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Pull lace to seat knot in
the far lace pocket, on the
opposite side of the green
marker.
Completely push knot
into the cavity with a #1
flathead screwdriver:
Remove both red lock
plugs to engage the Shift
feature of the reel.
a. b. c.
Pro Tip: Keep the red lock
plugs for future use or leave
in place to keep reel locked in
Power Mode.
Attach lace to the Click Reel.
Step 1
Test function.
Cycle the system 3 times before delivering to verify proper function.
2. Press the reel firmly into the collar (you
should hear a “CLICK” when secure).
CLICK!
Step 3
Step 5 Step 6
Step 4
Step 7
Relace the device.
Attach each lace to its
corresponding lace
port on the reel - A,
B, or C.
Step 2
Ensure that the reel is ready for
lacing. Both lock plugs should be in
place. The green marks on the spool
should align with the green marks on
the washer. If necessary, turn dial to
align green marks. Lock Plug
Lace Port C
Lace Port A
Lock Plug
Adjust alignment
by turning dial
Lace the reel using the
plastic lace feeder.
Pro Tip:
Gently pull the lace through
the cavity to avoid breaking
the plastic lace feeder
Tie a double overhand knot
and trim tail to ~5mm and
lightly burn the end of the tail.
Important.
As a final step of fabrication, attach the patient Instructions For Use hangtag on dial.
Green
Marker
Install the Click Reel.
Pull the free lace end to remove
loose lace from device.
Repeat Step 3 to feed the free
lace end through reel.
Measure out ~20cm of lace.
Repeat Step 4 to tie overhand
knot, trim, burn and seat it.
1. Insert the foot of the reel into the void in the
bottom of the collar opposite of the metal insert.
8
9
10
11

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How to use the Click Reel
Turn reel clockwise to
quickly take up lace.
Micro-adjust by turning
forward or backward.
To fully release, unwind
counterclockwise until
“clicking” stops.
Reel will automatically shift
to high power mode as it
tightens.
See clickmedical.co/instructions for detailed instructions for replacing/re-lacing a reel.
To remove the Click Reel:
a. Locate the metal insert.
b. Insert a small #1 flathead screwdriver
between the metal insert and the reel body.
c. Gently pry the reel upwards.
Metal Insert
Pull Out
Push In
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Teach your patients how to release and reconnect the releasing guides:
Release the Lace. Reconnect the Lace.
Fast Wind or Full Release
Mode = Silent (Smooth)
Power Mode =
“Clicking” (Tactile)
Pro Tip: If you prefer the reel to operate
ONLY in Power Mode for constant
micro-adjustment, replace the lock plug
to “disable” the Shift function.
At delivery of device with patient present, scan Instructions For Use Hangtag.
Please review with your patient how to use the Click Reel and to care for and
maintain their RevoSurface system.
This product is waterproof and submersible.
Rinse with fresh water after use in saltwater,
sand, or mud.
✔
✔
✔
Inspect lace:
Check for wear or damage routinely
Replace at any sign of wear
Replace lace every 6 months
Regularly inspect your RevoSurface system.

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Click Medical, LLC, 1205 Hilltop Parkway, W101
Steamboat Springs, CO 80487, USA [phone]
MDSS GmbH, Schiffgraben 41
30175 Hannover, Germany
CH
UK
MDSS CH GmbH, Laurenzenvorstadt 61
5000 Aarau, Switzerland
MDSS-UK RP LIMITED, 6 Wilmslow Road
Rusholme, M14 5TP Manchester
United Kingdom