Rail-Mounted Anatomic 3D Scanning Tube for Rapid Cast Design
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Solution Overview
Problem
Conventional casting methods for immobilizing injured body parts are inadequate due to water resistance issues, limited activity, skin irritation, and prolonged immobilization, while existing 3D scanning technologies are slow, costly, or lack precision and accuracy.
Innovation Solution
A 3D scanning system using laser beams and cameras captures high-precision 3D models of body parts in under 10 seconds, integrating backup cameras for blind spots, and software for automated cast and splint design, enabling rapid, accurate, and customizable orthopedic devices with integrated features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plaster casting methods are used, then immobilization is achieved quickly, but the cast is not water-resistant and limits patient activity
Solution Approach 1:
The patent applies porous materials by incorporating a lattice structure within the cast material. This lattice framework creates interconnected voids that allow water and air to pass through, making the cast water-resistant while maintaining structural integrity. The porous design enables patient activity freedom by allowing water penetration and air circulation, directly resolving the contradiction between quick immobilization and patient activity versatility.
2Ease of manufacture
If conventional plaster casts are used, then immobilization is achieved, but skin irritation and sweating occur due to lack of air flow
Solution Approach 1:
The lattice structure creates a porous network throughout the cast that facilitates air circulation and moisture wicking. This porous architecture allows sweat to evaporate and air to flow through the cast, preventing skin irritation and maceration while maintaining the simplicity of the casting process. The harmful effect of skin irritation is eliminated through the inherent breathability of the porous lattice design.
3Extent of automation
If laser scanners with robotic arms are used, then automated 3D scanning is achieved, but the scanning process takes 1-5 minutes requiring patient immobility
Solution Approach 1:
The patent segments the scanning system into multiple independent cameras positioned at different angles around the patient's body part. Each camera captures a portion of the anatomy simultaneously, eliminating the need for slow sequential scanning with a single laser line. This segmentation of the scanning function into parallel camera channels reduces scanning time from minutes to seconds while maintaining automation, directly addressing the contradiction between scanning automation and scanning duration.
4Productivity
If photogrammetry with 10-20 cameras is used, then 3D modeling is achieved quickly, but the system is costly and requires designated space
Solution Approach 1:
The patent applies universality by designing a multi-functional scanning system where a smaller number of cameras serve multiple purposes. The cameras are positioned and configured to capture various anatomical regions and angles, replacing the need for numerous dedicated cameras. This multi-functional approach maintains high scanning productivity while reducing device complexity and space requirements, as each camera performs multiple scanning functions rather than requiring specialized equipment for each viewing angle.
5Strength
If conventional casts are used, then immobilization is achieved, but the cast lacks breathability and water resistance
Solution Approach 1:
The patent employs composite materials by combining the lattice structure with appropriate casting materials to create a multi-phase composite cast. The lattice framework provides structural strength and immobilization, while the porous spaces filled with breathable, water-resistant material confer durability and environmental resistance. This composite architecture simultaneously achieves strong immobilization and enhanced reliability through water resistance and breathability, resolving the contradiction between cast strength and durability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides fast, precise, and customizable 3D models for orthopedic devices, reducing patient discomfort and immobilization time, while ensuring accuracy and durability against contaminants.
Implementation Method 1
a laser scanner that emits laser beams on the object and captures the reflections by a number or array of cameras
Data Source
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AI summary
A scanner system for capturing a three-dimensional model of an object includes a laser and a camera to capture two-dimensional images of the object. The system also includes a tube mounted to a rail, a central processor configured to receive data collected from the laser and the camera and an actuation mechanism configured to move the tube along the rail. The tube is configured to move generally along a travel axis of the rail. The tube includes open first and second tube ends. The laser and camera are mounted inside the tube between the first and second tube ends. The first tube end includes a first continuous ring and the second tube end includes a second continuous ring. A channel extends through the tube between the first and second rings positioned adjacent the rail in an assembled configuration.