Ear malformation correction training model and manufacturing method thereof

Abstract

The invention discloses an ear malformation correction training model and a manufacturing method thereof. According to the method, through precise 3D scanning and an advanced three-dimensional reconstruction technology and in combination with an SLA 3D printing technology, the ear malformation correction training model can be directly printed in one step from a digital model. The advantage of this one-step molding is that it avoids the complexity and errors of multi-step assembly and joining that may occur in conventional manufacturing methods. And each model is integrally formed, so that the accuracy of the model and the integrity of the structure are ensured. The method not only improves the production efficiency, but also reduces the possibility of human errors, thereby improving the reliability and training effect of the model. By using advanced materials and a fine 3D printing technology, the highly simulated model not only improves the authenticity of training, but also allows doctors to practice and test different surgical techniques and methods under different conditions, thereby improving surgical skills and surgical success rate.

Description

Technical Field

[0001] The invention belongs to the technical field of medical teaching aids, and in particular relates to an ear deformity correction training model and a manufacturing method thereof. Background Art

[0002] Patients with external ear deformities (protruding ears, cup-shaped ears, Stahls / ape ears) need to undergo ear plastic surgery or even reconstructive surgery for treatment. In ear plastic surgery, the correction operation requires high precision and difficulty, and is one of the most challenging operations in ear plastic surgery. Behind the doctor's efficient completion of this technical operation, a lot of time is needed to simulate and practice ear deformity correction. Existing training models include easily accessible pig cartilage, as well as specially made polyurethane 3D printed models and silicone casting models. Polyurethane 3D printing model technology: ① Use a 3D camera to perform a three-dimensional scan of the patient's external ear deformity ② Extract the external ear deformity (protruding ears, cup-shaped ears, Stahls / ape ears) model and perform model post-processing ③ Polyurethane 3D printing, use TPU material for 3D printing to obtain the required model. AGILUS 30FLX935 POLYJET SLA 3D printing model: ①Use 3D camera to perform 3D scanning of the patient's external ear deformity ②Extract the external ear deformity (protruding ears, cup ears, Stahls / ape ears) model and perform model post-processing ③AGILUS 30FLX935 3D printing, use AGILUS 30FLX935 material for 3D printing to obtain the required model. Silicone casting molding: ①Use 3D camera to perform 3D scanning of the patient's external ear deformity to obtain data and post-process, design the mold of the ear deformity 3D model ②3D print to make a metal mold ③Liquid material casting ear deformity model ④Demolding, obtain the ear deformity model.

[0003] However, the shape of natural materials (pig rib cartilage) is very different from human ear bones. Doctors cannot simulate the surgical operation environment well during practice, and the practice effect is not good. The texture of polyurethane and silicone cast ear deformity model materials is still different from human ear cartilage, especially in flexibility and sutureability. In view of the above problems, the present invention aims to simulate the human ear cartilage during surgery in terms of appearance and texture, and improve the problem of insufficient flexibility and sutureability of the model in the existing technical solutions. Summary of the invention

[0004] The purpose of the present invention is to provide an ear deformity correction training model and a manufacturing method thereof in order to solve the above-mentioned problems.

[0005] The technical solution adopted by the present invention is as follows: a method for manufacturing a training model for ear deformity correction, the manufacturing method comprising the following steps:

[0006] Step 1: Construction of a three-dimensional model of ear deformity (protruding ears, cup-shaped ears, ape ears) based on a 3D camera.

[0007] Step 1.1 Collect 3D scan photos of ear deformities (protruding ears, cup-shaped ears, and ape ears).

[0008] Step 1.2: Materialise mimics is used to extract the ear deformity (protruding ears, cup-shaped ears, and ape ears) model, and the model is post-processed to construct the final ear deformity model.

[0009] Step 2: 3D print the ear deformity (protruding ears, cup-shaped ears, ape ears) model. Use SLA (stereolithography) printing: use agilus 30A, 40A, 50A, 60A, 70A, 85A, 95A materials for printing.

[0010] Step 2.1 Model preparation: Use computer-aided design software to design the ear deformity model to be printed and convert it into the required file format. The file contains the geometric information of the model for slicing and printing.

[0011] Step 2.2 Slicing and path generation: Slice the file into multiple thin layers and generate a sequence of photolithography layer thicknesses.

[0012] Step 2.3 Liquid photosensitive resin solidification: The laser beam is irradiated onto the liquid photosensitive resin layer by layer, causing it to gradually solidify into a solid layer. Each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model.

[0013] Step 2.4 Print layer by layer: Repeat the coating and curing steps until the entire model is printed.

[0014] Step 2.5 Post-processing: remove the uncured resin, perform surface finishing, and then collect the obtained models, thus completing the entire manufacturing process of the ear deformity correction training model.

[0015] In a preferred embodiment, the step 1.1 specifically includes the following steps:

[0016] Preparation: Make sure the 3D camera is calibrated correctly and the ambient light is suitable to obtain high-quality scan images.

[0017] Scanning process: Instruct the patient to sit or stand in front of the 3D camera and keep the head steady so that an accurate image of the ear can be captured.

[0018] Image acquisition: Use a 3D camera to photograph the ear from different angles to obtain sufficient data for the construction of a three-dimensional model.

[0019] In a preferred embodiment, the step 1.2 specifically includes the following steps:

[0020] Data import: Import the ear image data taken by the 3D camera into the Materialise Mimics software.

[0021] Three-dimensional reconstruction: Use the three-dimensional reconstruction function of the software to generate a three-dimensional model of the ear based on the image data.

[0022] Model optimization: Smooth the reconstructed 3D model, remove unnecessary noise, and optimize the model structure.

[0023] Model Validation: Check the accuracy of the model to ensure that it matches the actual ear structure.

[0024] In a preferred embodiment, the step 2.1 specifically includes the following steps:

[0025] Fix geometry issues: Check and repair possible geometric errors in your model in your CAD software, such as holes, overlaps or gaps.

[0026] Model positioning: Ensure the correct position and orientation of the model on the printing platform for easy printing and post-processing.

[0027] In a preferred embodiment, the step 2.2 specifically includes the following steps:

[0028] Select slice parameters: Set slice thickness, print speed, laser power and other parameters to meet specific printing needs.

[0029] Generate printing path: The software will calculate the movement path of the laser beam on each layer to ensure accurate printing of the model.

[0030] In a preferred embodiment, the step 2.3 specifically includes the following steps:

[0031] Prepare resin: Select the appropriate resin type, such as agilus 30A, 40A, 50A, 60A, 70A, 85A, 95A, and pour it into the resin tank in the printer.

[0032] Start curing: The laser beam irradiates the resin along the slicing path, and each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model.

[0033] In a preferred embodiment, the step 2.4 specifically includes the following steps:

[0034] Monitor the printing process: Monitor the formation of the model during the printing process to ensure that no printing errors occur.

[0035] Support structures: For parts with overhangs or complex structures, you may need to add support structures to keep the model stable during printing.

[0036] In a preferred embodiment, the step 2.5 specifically includes the following steps:

[0037] Cleaning the Model: Using appropriate solvents and tools, carefully remove any uncured resin and support structures from the surface of the model.

[0038] Surface treatment: Sand, polish or coat the model as needed to improve its surface finish and durability.

[0039] Inspection and Verification: Finally, the printed ear deformity model is inspected to ensure that it meets the accuracy and quality requirements for medical applications.

[0040] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0041] 1. In the present invention, through precise 3D scanning and advanced three-dimensional reconstruction technology, combined with SLA 3D printing technology, the ear deformity correction training model can be printed directly from the digital model in one step. The advantage of this one-step molding is that it avoids the complexity and errors of multi-step assembly and joining that may occur in traditional manufacturing methods. Each model is integrally molded to ensure the accuracy of the model and the integrity of the structure. This method not only improves production efficiency, but also reduces the possibility of human error, thereby improving the reliability of the model and the training effect.

[0042] 2. In the present invention, by using advanced materials and sophisticated 3D printing technology, the method can produce a training model that is very close to the appearance and texture of real human rib cartilage. The ear structure of this model has elasticity, texture and color similar to real rib cartilage, allowing surgeons to have a more realistic and intuitive experience when conducting surgical training. This highly simulated model not only improves the authenticity of training, but also allows doctors to practice and test different surgical techniques and methods under different conditions, thereby improving surgical skills and surgical success rates.

[0043] 3. In the present invention, the material used has excellent toughness, so that the training model can better withstand the stress of suturing and operation during the simulated surgery. The superior performance of this material enables the model to show better durability and stability in repeated use and simulated surgical operations. In addition, due to the excellent suturing performance of the material, doctors can perform suturing exercises on the model many times to master and improve suturing skills. This highly realistic simulation environment not only improves doctors' surgical skills, but also provides them with a safe and controllable platform to experiment and improve new surgical techniques and methods. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0045] Example:

[0046] A method for manufacturing an ear deformity correction training model, the manufacturing method comprising the following steps:

[0047] Step 1: Construction of a three-dimensional model of ear deformity (protruding ears, cup-shaped ears, ape ears) based on a 3D camera.

[0048] Step 1.1 Collect 3D scan photos of ear deformities (protruding ears, cup-shaped ears, and ape ears).

[0049] Step 1.2: Materialise mimics is used to extract the ear deformity (protruding ears, cup-shaped ears, and ape ears) model, and the model is post-processed to construct the final ear deformity model.

[0050] Step 2: 3D print the ear deformity (protruding ears, cup-shaped ears, ape ears) model. Use SLA (stereolithography) printing: use agilus 30A, 40A, 50A, 60A, 70A, 85A, 95A materials for printing.

[0051] Step 2.1 Model preparation: Use computer-aided design software to design the ear deformity model to be printed and convert it into the required file format. The file contains the geometric information of the model for slicing and printing.

[0052] Step 2.2 Slicing and path generation: Slice the file into multiple thin layers and generate a sequence of photolithography layer thicknesses.

[0053] Step 2.3 Liquid photosensitive resin solidification: The laser beam is irradiated onto the liquid photosensitive resin layer by layer, causing it to gradually solidify into a solid layer. Each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model.

[0054] Step 2.4 Print layer by layer: Repeat the coating and curing steps until the entire model is printed.

[0055] Step 2.5 Post-processing: remove the uncured resin, perform surface finishing, and then collect the obtained models, thus completing the entire manufacturing process of the ear deformity correction training model.

[0056] Step 1.1 specifically includes the following steps:

[0057] Preparation: Make sure the 3D camera is calibrated correctly and the ambient light is suitable to obtain high-quality scan images.

[0058] Scanning process: Instruct the patient to sit or stand in front of the 3D camera and keep the head steady so that an accurate image of the ear can be captured.

[0059] Image acquisition: Use a 3D camera to photograph the ear from different angles to obtain sufficient data for the construction of a three-dimensional model.

[0060] Step 1.2 specifically includes the following steps:

[0061] Data import: Import the ear image data taken by the 3D camera into the Materialise Mimics software.

[0062] Three-dimensional reconstruction: Use the three-dimensional reconstruction function of the software to generate a three-dimensional model of the ear based on the image data.

[0063] Model optimization: Smooth the reconstructed 3D model, remove unnecessary noise, and optimize the model structure.

[0064] Model Validation: Check the accuracy of the model to ensure that it matches the actual ear structure.

[0065] Step 2.1 specifically includes the following steps:

[0066] Fix geometry issues: Check and repair possible geometric errors in your model in your CAD software, such as holes, overlaps or gaps.

[0067] Model positioning: Ensure the correct position and orientation of the model on the printing platform for easy printing and post-processing.

[0068] Step 2.2 specifically includes the following steps:

[0069] Select slice parameters: Set slice thickness, print speed, laser power and other parameters to meet specific printing needs.

[0070] Generate printing path: The software will calculate the movement path of the laser beam on each layer to ensure accurate printing of the model.

[0071] Step 2.3 specifically includes the following steps:

[0072] Prepare resin: Select the appropriate resin type, such as agilus 30A, 40A, 50A, 60A, 70A, 85A, 95A, and pour it into the resin tank in the printer.

[0073] Start curing: The laser beam irradiates the resin along the slicing path, and each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model.

[0074] Step 2.4 specifically includes the following steps:

[0075] Monitor the printing process: Monitor the formation of the model during the printing process to ensure that no printing errors occur.

[0076] Support structures: For parts with overhangs or complex structures, you may need to add support structures to keep the model stable during printing.

[0077] Step 2.5 specifically includes the following steps:

[0078] Cleaning the Model: Using appropriate solvents and tools, carefully remove any uncured resin and support structures from the surface of the model.

[0079] Surface treatment: Sand, polish or coat the model as needed to improve its surface finish and durability.

[0080] Inspection and Verification: Finally, the printed ear deformity model is inspected to ensure that it meets the accuracy and quality requirements for medical applications.

[0081] The ear deformity correction training model is prepared by the above method.

[0082] In the present invention, through accurate 3D scanning and advanced three-dimensional reconstruction technology, combined with SLA 3D printing technology, the ear deformity correction training model can be printed directly from the digital model in one step. The advantage of this one-step molding is that it avoids the complexity and errors of multi-step assembly and joining that may occur in traditional manufacturing methods. Each model is integrally molded to ensure the accuracy of the model and the integrity of the structure. This method not only improves production efficiency, but also reduces the possibility of human error, thereby improving the reliability of the model and the training effect.

[0083] In the present invention, by using advanced materials and sophisticated 3D printing technology, the method can produce a training model that is very close to the appearance and texture of real human rib cartilage. The ear structure of this model has elasticity, texture and color similar to real rib cartilage, allowing surgeons to have a more realistic and intuitive experience when performing surgical training. This highly simulated model not only improves the authenticity of training, but also allows doctors to practice and test different surgical techniques and methods under different conditions, thereby improving surgical skills and surgical success rates.

[0084] In the present invention, the material used has excellent toughness, so that the training model can better withstand the stress of suturing and operation during the simulated operation. The superior performance of this material enables the model to show better durability and stability in repeated use and simulated surgical operations. In addition, due to the excellent suturing performance of the material, doctors can perform suturing exercises on the model many times to master and improve suturing skills. This highly realistic simulation environment not only improves the surgical skills of doctors, but also provides them with a safe and controllable platform to experiment and improve new surgical techniques and methods.

[0085] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or still includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "including one..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0086] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing an ear deformity correction training model, characterized in that: The manufacturing method comprises the following steps: Step 1: Construction of a three-dimensional model of ear deformity based on a 3D camera; Step 1.1 Collect 3D scan photos of ear deformity; Step 1.2: materialise mimics is used to extract the ear deformity model, and the model is post-processed to construct the final ear deformity model; Step 2: 3D print the ear deformity model; use stereolithography to print: use agilus30A, 40A, 50A, 60A, 70A, 85A, 95A materials for printing; Step 2.1 Model preparation: Use computer-aided design software to design the ear deformity model to be printed and convert it into the required file format; the file contains the geometric information of the model for slicing and printing; Step 2.2 Slicing and path generation: Slice the file into multiple thin layers and generate a sequence of photolithography layer thicknesses; Step 2.3 Liquid photosensitive resin solidification: The laser beam is irradiated onto the liquid photosensitive resin layer by layer, so that it gradually solidifies into a solid layer; each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model; Step 2.4 Print layer by layer: Repeat the coating and curing steps until the entire model is printed; Step 2.5 Post-processing: remove the uncured resin, perform surface finishing, and then collect the obtained models, thus completing the entire manufacturing process of the ear deformity correction training model.

2. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 1.1 specifically includes the following steps: Preparation: Ensure that the 3D camera is accurately calibrated and the ambient light is appropriate to obtain high-quality scan images; Scanning process: Instruct the patient to sit or stand in front of the 3D camera and keep the head stable so that an accurate ear image can be captured; Image acquisition: Use a 3D camera to photograph the ear from different angles to obtain sufficient data for the construction of a three-dimensional model.

3. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 1.2 specifically includes the following steps: Data import: Import the ear image data taken by the 3D camera into the Materialise Mimics software; 3D reconstruction: Use the 3D reconstruction function of the software to generate a 3D model of the ear based on the image data; Model optimization: Smooth the reconstructed 3D model, remove excess noise, and optimize the model structure; Model Validation: Check the accuracy of the model to ensure that it matches the actual ear structure.

4. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 2.1 specifically includes the following steps: Repair geometry issues: Check and repair possible geometry errors in the model in CAD software, including holes, overlaps or gaps; Model positioning: Ensure the correct position and orientation of the model on the printing platform for easy printing and post-processing.

5. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 2.2 specifically includes the following steps: Select slice parameters: set slice thickness, printing speed, laser power and other parameters to meet specific printing requirements; Generate printing path: The software will calculate the movement path of the laser beam on each layer to ensure accurate printing of the model.

6. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 2.3 specifically includes the following steps: Prepare the resin: select the appropriate resin type, agilus 30A, 40A, 50A, 60A, 70A, 85A, 95A, and pour it into the resin tank in the printer; Start curing: The laser beam irradiates the resin along the slicing path, and each layer solidifies to form a thin sheet, which is gradually stacked to form the entire model.

7. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 2.4 specifically includes the following steps: Monitor the printing process: monitor the formation of the model during the printing process to ensure that no printing errors occur; Support structures: For parts with overhangs or complex structures, you may need to add support structures to keep the model stable during printing.

8. The method for manufacturing an ear deformity correction training model according to claim 1, characterized in that: The step 2.5 specifically includes the following steps: Cleaning the model: Use appropriate solvents and tools to carefully remove uncured resin and support structures from the surface of the model; Surface treatment: grinding, polishing or coating the model as needed to improve its surface finish and durability; Inspection and Verification: Finally, the printed ear deformity model is inspected to ensure that it meets the accuracy and quality requirements for medical applications.

9. A training model for ear deformity correction, characterized in that: The model is prepared by the method according to any one of claims 1 to 8.