Clavicle Protective Device Design With 3D-Printed Fit

The patent transforms the customization process by changing parameters from manual measurement and physical molding to digital 3D scanning and computer-aided design. The system captures precise anatomical data through 3D scanning, processes it through software algorithms, and generates customized protective devices through additive manufacturing, achieving high fit accuracy while maintaining manufacturing efficiency.

The patent replaces manual mechanical processes (hand molding, plaster casting) with automated digital systems. Instead of physically molding materials around the body part, the system uses optical 3D scanning to capture geometry, then computationally generates the protective device design, eliminating the need for manual skill and physical trial-and-error.

The patent employs additive manufacturing to create protective devices with complex multi-material structures that would be impossible to achieve through hand molding. The digital design process allows integration of different materials with complementary properties (e.g., flexible polymers for comfort, rigid reinforcement elements for protection) in a single manufacturing process, overcoming the material constraints of traditional thermoplastic substrates.

The patent transitions from two-dimensional hand-molded surfaces to three-dimensionally optimized structures through digital modeling. The additive manufacturing process enables creation of complex internal geometries, lattice structures, and multi-layer composite configurations that provide enhanced mechanical properties while maintaining customization, effectively adding design freedom in multiple spatial dimensions.

The patent performs all preparatory actions digitally before physical manufacturing. The 3D scan is captured once, the anatomical data is processed and stored, and the protective device design is computationally generated and optimized in advance. This digital preliminary action eliminates the need for repeated physical trial-and-error molding processes, significantly reducing the overall time required to produce customized protective devices.

The patent creates a precise digital copy of the body part through 3D scanning, which serves as the basis for all subsequent design iterations and manufacturing. This digital copy can be manipulated, modified, and reproduced infinitely without the time-consuming physical processes required by plaster molding, enabling rapid prototyping and production of customized protective devices.

The patent applies different material properties and structural characteristics to different regions of the protective device based on local requirements. Through digital modeling, the design can incorporate flexible materials in areas requiring movement and rigid reinforcement in areas requiring protection. The additive manufacturing process enables precise placement of different materials or structural elements at specific locations, achieving optimal balance between protection and mobility.

The patent designs protective devices with dynamic characteristics that allow them to adapt to movement. The digital design process enables integration of flexible joints, movable segments, and compliant materials that permit natural range of motion while maintaining protection. The protective device can be designed to flex, bend, or move with the body part rather than restricting it, achieving both injury prevention and ease of operation.