3D Printed Anatomical Copies Using Digital CT Acquisition
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Solution Overview
Problem
Current methods for copying anatomical segments are prone to errors due to tissue movement during mould preparation, are invasive for patients, and involve hazardous chemicals, leading to prolonged and uncomfortable procedures with reduced precision and increased production time.
Innovation Solution
The method employs high-definition digital acquisition techniques such as orthopantomographs and CT scans to create precise three-dimensional models, which are then printed using additive stratification devices with colored silicone materials to produce accurate, non-invasive, polychromatic copies of anatomical segments, eliminating the need for traditional casting and hazardous substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting techniques with silicones and alginates are used to copy anatomical segments, then a physical mould can be obtained, but tissue movement during mould preparation causes high error rates and reduced precision
Solution Approach 1:
The patent replaces the mechanical casting system (silicones, alginates, physical moulds) with a digital acquisition system (orthopantomographs, CT scans, 3D imaging). This substitution eliminates the mechanical contact and manipulation of tissues that causes movement and errors, achieving higher precision and reliability through non-contact digital modeling.
Solution Approach 2:
The patent creates a digital copy (3D model) of the anatomical segment instead of a physical mould copy. This digital replication allows for unlimited repetitions without degradation, eliminates material deformation issues, and enables precise measurement and analysis without physical manipulation of the original tissues.
2Manufacturing precision
If traditional cast preparation is performed to ensure proper negative reproduction, then the anatomical structure can be captured, but the patient must remain in uncomfortable positions for long periods causing stress and discomfort
Solution Approach 1:
The patent replaces the mechanical restraint system required for traditional casting with a rapid digital imaging system. The orthopantomograph and CT scanner can capture the anatomical structure in seconds without requiring the patient to maintain fixed positions, thereby maintaining accuracy while dramatically improving comfort and ease of operation.
Solution Approach 2:
The patent performs the acquisition in a single preliminary action using advanced imaging technology, eliminating the need for prolonged positioning and multiple adjustment steps required in traditional casting. The digital model is captured completely in one procedure, reducing patient stress and improving ease of operation.
3Ease of manufacture
If traditional casting materials and chemicals are used to prepare moulds, then the anatomical copy can be produced, but hazardous substances like methyl methacrylate vapors contaminate the work environment
Solution Approach 1:
The patent replaces the chemical-based casting process with a digital acquisition and 3D printing process. This substitution eliminates all hazardous chemicals (silicones, alginates, methyl methacrylate vapors) from the workflow, maintaining full copy production capability while completely removing chemical contamination risks from the work environment.
Solution Approach 2:
The patent uses digital data as a disposable, non-hazardous medium that can be replicated indefinitely without degradation. Unlike physical moulds and chemical materials that require storage, handling, and disposal, the digital model can be stored indefinitely without any environmental contamination, eliminating harmful factors while maintaining manufacturing capability.
4Manufacturing precision
If multiple operations are performed to prepare the mould and cast the copy, then the anatomical segment can be reproduced, but the production time is prolonged
Solution Approach 1:
The patent merges multiple separate operations (positioning, mould preparation, casting, finishing) into a single integrated digital acquisition and 3D printing process. The digital model captures all anatomical details in one scan, and the 3D printer directly produces the copy without intermediate steps, thereby maintaining high accuracy while dramatically increasing productivity and reducing production time.
Solution Approach 2:
The patent enables continuous acquisition and production without interruption. The digital imaging system continuously captures data during the scan, and the 3D printer continuously builds the copy layer by layer, eliminating the stop-start nature of traditional casting operations. This continuous process maintains precision while accelerating production speed.
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
This approach significantly reduces errors, minimizes patient stress, and accelerates the production of anatomical implants while enhancing precision and accuracy, allowing for the development of tailored operating strategies and non-destructive forensic examinations.
Implementation Method 1
three-dimensional printing device suitable to make a copy of the anatomical segment
Implementation Method 2
high-definition computed tomography devices or three-dimensional X-ray devices
Implementation Method 3
three-dimensional X-ray devices
Data Source
AI summary
A method for copying and reproducing patient's anatomical segments comprises the following steps: - taking a three-dimensional acquisition of the anatomical segment to be reproduced; - digitally saving the data of the three-dimensional acquisition; - sending such digital data to a three-dimensional printing device suitable to reproduce a copy of the anatomical segment; - identifying in the digital data the volumes corresponding to the different anatomical tissue that form the acquired anatomical segment and identifying them with different colors or properties; - deposing in layer sequence some polymeric material colored according to the tissue to be copied; - using silicon based polymeric material having a density comparable with the density of the tissue to be copied.