3D CAM Flight Gear Fitting Using Anatomical Surface Models
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Solution Overview
Problem
Military applications for three-dimensional (3D) computer-aided manufacturing (CAM) of equipment and garments for soldiers and airmen face challenges due to reliance on manual measurements and standard size rolls, leading to labor-intensive, error-prone fitting processes.
Innovation Solution
A system and method utilizing a scanner to capture digital 3D surface models of soldiers or airmen, recognizing anatomical features, and using computational geometry to create custom 3D pilot flight equipment and garments through computer-aided manufacturing (CAM) devices, ensuring precise fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual tailor measurements and standard size rolls are used, then the fitting process can be performed with simple equipment, but the process becomes labor and time intensive with high error rates
Solution Approach 1:
The patent replaces manual mechanical measurement processes with automated 3D scanning technology. The system uses optical scanners to capture precise anatomical data of the soldier's head and body, eliminating the need for manual tailor measurements. This substitution of mechanical measurement with automated scanning directly resolves the contradiction by providing high precision fitting data while dramatically reducing the time and labor required for the fitting process.
Solution Approach 2:
The patent transforms the fitting process from using discrete manual measurement parameters to comprehensive 3D spatial parameters. By capturing the entire surface geometry of the soldier's anatomy through 3D scanning, the system obtains detailed parametric data including head circumference, facial features, and body contours. This parameter transformation enables precise digital modeling and customization of equipment while reducing fitting time through automated data processing.
2Manufacturing precision
If manual measurements and standard sizes are used, then the system complexity remains low, but the fitting accuracy and customization capability deteriorate
Solution Approach 1:
The patent creates accurate digital 3D copies of the soldier's anatomy through scanning. The system generates digital surface models and volumetric representations that precisely replicate the soldier's head and body geometry. These digital copies serve as the basis for custom equipment design and manufacturing, enabling high precision fitting while managing system complexity through virtual modeling rather than physical prototyping.
Solution Approach 2:
The patent performs preliminary 3D scanning and digital modeling of the soldier's anatomy before equipment manufacturing. By capturing and processing anatomical data in advance, the system establishes precise digital templates that guide subsequent equipment customization. This preliminary action enables high manufacturing precision by ensuring accurate fit data is available before production begins, while reducing overall system complexity through upfront data acquisition.
3Adaptability or versatility
If 3D scanning and digital modeling are implemented, then fitting precision and customization improve, but the device complexity and initial resource requirements increase
Solution Approach 1:
The patent implements a universal 3D scanning and digital modeling system that can accommodate multiple types of military equipment and various soldier anatomies. The same scanning infrastructure and software platform are used to create custom fits for helmets, body armor, flight suits, and other gear. This multi-functional approach enhances adaptability and customization capability while managing device complexity by consolidating technology rather than requiring separate systems for each application.
Data Source
AI summary
A system comprising a scanner to scan the airman or soldier (subject), a processor to receive, from the scanner, a non-manifold three-dimensional (3D) digital surface model (DSM) scan data representative of the subject, and a computer-aided manufacturing (CAM) device. The processor recognizes anatomical features on the 3D surface model including the cephalic (head) region of the scanned subject; stores each sub region defined by anatomical features as a non-manifold 3D surface model; creates a surface offset from the DSM sub region; creates a closed volume within and between the DSM sub region and the offset surface representative of a solid 3D pilot flight equipment; and causes a computer-aided manufacturing (CAM) device to manufacture the solid 3D pilot flight equipment.