3D-Printed Orthotic Inserts From Mobile Foot Geometry Capture
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Solution Overview
Problem
Current methods for producing orthotic devices are slow, expensive, and limited in customizability, often resulting in one-size-fits-all solutions that do not optimally address individual patient needs, and are restricted to machining hard materials, which limits the range of characteristics such as flexibility and shock absorption.
Innovation Solution
A method that uses client devices to capture patient data, including image and inertial measurement data, to generate three-dimensional models of body parts, which are then used to create parametric CAD models for customized orthotic devices that can be 3D printed, allowing for variable density and patient-specific mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional plaster cast, gait scanning, or laser scanning methods are used to capture plantar geometry, then orthotic data can be obtained, but the process is slow, expensive, and limited in the range of characteristics provided to the resulting orthotic device
Solution Approach 1:
The patent replaces traditional mechanical scanning systems (plaster casts, gait scanning, laser scanning) with a mobile imaging system using cameras and image processing algorithms. This substitution enables rapid capture of plantar geometry through multiple images taken during natural foot movement, eliminating the time-consuming mechanical scanning process while maintaining measurement accuracy through computational methods.
2Ease of manufacture
If traditional machining methods are used to produce orthotic inserts, then hard materials can be processed, but the range of characteristics (flexibility, shock absorption, weight) is limited
Solution Approach 1:
The patent employs 3D printing technology that allows continuous variation of material parameters including density, flexibility, and shock absorption properties. The system can produce orthotic inserts with graded density distributions and variable material characteristics throughout the device, enabling customization of mechanical properties to match specific patient needs while maintaining manufacturing efficiency.
3Productivity
If orthotic insert shapes are mixed and matched from a database, then production is simplified, but the orthotic inserts are unique to a particular lab or production facility rather than to a particular patient
Solution Approach 1:
The patent captures and stores the patient's actual foot geometry and movement characteristics through mobile imaging before production begins. This preliminary data collection creates a digital template specific to each patient, which is then used to generate customized orthotic designs that perfectly match the individual's anatomy and biomechanics, eliminating the need for post-production customization while maintaining high production efficiency.
Data Source
AI summary
A method for generating an orthotic device is disclosed. The method includes receiving data from a client device of a patient, the data comprising patient information and image data representative of a body part of the patient. The method further includes generating, based on the image data, three-dimensional model data representative of the body part, and generating parametric CAD model data of the orthotic device based on the three-dimensional model data and the patient information. The parametric CAD model data is transmitted to a three-dimensional printer, wherein the three-dimensional printer is to generate the orthotic device based on the parametric CAD model data.