Coyote Composite

A few years ago we made the switch to using basalt braid (Coyote Composite) rather than carbon fiber for our laminations.

We did this for a more flexible tougher lamination but ended up with other benefits as well. Mainly a safer material that doesn’t itch the way carbon does, and it costs less.

It does laminate almost exactly the same, but there are some subtle differences in saturation. We have a lot of tips and tricks to help ensure you can laminate easily and effectively with Coyote Composite, and we can save you money.

Now Is the time to provide a safer work environment and save money.

  •  Extremely durable
  •  Resistant to cracking
  •  Less itch than carbon
  •  Non-carcinogenic and non-toxic
  •  Strong and lightweight
  •  Finishes smooth, with superior resin saturation
  •  Unique dampening characteristics
  •  Less expensive

Composite on outside of lay-up

RESIN   Coyote Composite works with typical prosthetic resins and saturates much better than carbon.

SATURATION AND LAMINATING   Because of its superior saturation it’s important to prevent resin starvation. Lamination starvation will cause frayed edges.

FINISHING   Coyote Composite finishes easily except in cases of starved laminations. Use sharp tooling at slow speeds to finish. In some cases, you may need to wet-sand.

RELIEVING   Coyote Composite is heat- and flame-resistant and isn’t damaged by heating. It allows for LIMITED adjustment based on the type of resin used.

SAFETY   Because of the inert nature of basalt, it is not a carcinogen. Also, Coyote Composite is between 9 and 16 micrometers in diameter, which is too large to be an inhalant risk. Basalt also causes significantly less skin irritation.

Composite on inside of lay-up

Composite Rope can be in reinforcing sockets or AFOs

BRAID   Our proprietary braid was designed to be used in equivalent amounts to carbon. Coyote Composite is more flexible than carbon (we consider this to be an advantage), but if you need to match the rigidity of a carbon socket, use additional layers of stockinette and/or carbon tape.

FABRIC   Coyote Composite fabric sheeting can be used for reinforcement layers of heavy duty sockets and/or AFOs. The material is thin and lightweight which allows for greater flexibility in adding the ideal amount of reinforcement.

ROPE   We use Coyote Composite rope as a reinforcement material in place of (or in conjunction with) carbon tape. This can be used for distal reinforcement or spot reinforcing in windowed sockets.

Billing Information – Recommended Codes

L5940   Addition, endoskeletal system, Below Knee, Ultra-Light material (Titanium, carbon fiber or equal),

L5950   Addition, endoskeletal system, Above Knee, Ultra-Light material (Titanium, carbon fiber or equal),

L7400   Addition to upper extremity prosthesis, below elbow / wrist disarticulation, ultra light material (Titanium, carbon fiber or equal)

L2755   Addition to lower extremity orthosis, high strength, light weight material, all hybrid lamination / prepreg composite, per segment, for custom fabricated orthosis only.

The listing of codes with our products should not be construed as a guarantee for coverage or payment.

Ultimate responsibility for the coding of services/products rests with the individual practitioner.


Take our “Alternatives to Carbon Fiber” course at

Get access to new techniques and methods right form your office or home through our first-level educational programs available on-line. For more information go to


You will have a better understanding of the different properties of composite materials

2.5 (S) CE credits course – Currently No Charge


– Vacuum & Resins with Coyote CompositeTips on Vacuum, resin and lay-up

We typically use two layers of basalt, with basic nylon stockinette in different order depending on the finish, and carbon tape over the distal end

Epoxy resin run full vacuum at 20 to 24 in/HG until everything is saturated and cured.

Very important to follow resin manufacturers instructions for proper measurements and mixing

Epoxy resin manufacturers typically recommend a heat bag.

Finishing Edge Using Coyote Composite

Coyote Composite edges finish smoother and tend to be less jagged than carbon fiber.

Use the roughest sanding cone to take the edge down to the trim lines.

Use medium scotch bright wheel, buff outside to inside, inside to outside, smoothing and rounding off edges.

When polishing and finishing slow speed may give better results.

Finish with Tycro wheel. If you want more do a wet sand with scotch bright.

Acrylic modified epoxy resin run full vacuum at  20 to 24 in/HG until everything is saturated. When done stringing and walking away turn vacuum down to 10 to 15 in/HG.


Layups are affected by the type of resin used. Modified Acrylic; thinner, easier to saturate, fast cure time. Epoxy Resin; stronger, clearer, thicker, slower cure time. Epoxy works well for heavier and more active people.


Use equal amounts of Coyote Composite in place of carbon fiber in your existing layups, or you can try one of Coyote Designs sample layups.

How you lay it up will also greatly change the strength weight and flexibility.

Coyote Composite is Tough Stuff

Watch this video of Nick Edinger “World’s Strongest Adaptive Athlete 2016” and see how tough Coyote Composite is and what other properties this power lifter found useful about Coyote Composite and Coyote’s StabileFlex Socket Design.