3D CAM Flight Gear From Body Scans for Precise Pilot Fit
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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) processes, ensuring precise fit and reducing errors.
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 an automated 3D scanning system that captures digital surface models. The scanner automatically extracts anthropometric data from the 3D scan, eliminating manual measurement errors and reducing fitting time while improving precision.
Solution Approach 2:
The patent creates a digital copy (3D surface model) of the subject's body geometry. This digital model is then used to generate custom-fit garment patterns and equipment designs, allowing multiple measurements and design iterations without additional physical measurement time.
2Manufacturing precision
If custom-fit equipment and garments are manufactured for each individual, then the fit quality improves, but the manufacturing complexity and time increase
Solution Approach 1:
The system captures complete 3D geometric parameters of the subject and uses these parameters to drive automated pattern generation and manufacturing. By changing from manual parameter measurement to automated 3D scanning, the system maintains custom-fit precision while improving manufacturing efficiency through digital workflow integration.
Solution Approach 2:
The patent performs preliminary 3D scanning and digital model creation before the actual manufacturing process. This preliminary digital preparation allows for automated pattern generation and manufacturing planning, reducing on-site manufacturing time and complexity while maintaining custom-fit quality.
3Measurement precision
If 3D scanning and automated processing systems are implemented, then measurement accuracy and manufacturing efficiency improve, but the system complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single 3D scanning device performs multiple functions: capturing surface geometry, extracting anthropometric measurements, generating 3D models, and guiding manufacturing processes. This universal approach improves measurement accuracy while managing system complexity through consolidation rather than multiple separate systems.
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.