Automated Trim Line Generation for Cranial Remodeling Devices
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Solution Overview
Problem
The existing methods for cranial remodeling devices require manual intervention and operator expertise for data reorientation and selection, leading to inconsistent results and inefficiencies in producing custom cranial remodeling devices.
Innovation Solution
A system and method utilizing databases of three-dimensional digital data for trim lines, trained support vector machines, and iterative differential evolution to automatically generate and optimize trim lines for cranial remodeling devices, enabling precise and efficient production of custom devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual reorientation and selection of DSI captured data is performed by trained operators, then the process can accommodate individual subject variations and clinical adaptations, but the process becomes time-consuming and produces inconsistent results
Solution Approach 1:
The patent replaces the manual mechanical process of operator intervention with an automated computer-based system. The system automatically reorients DSI captured data files to predetermined orientations and selects portions of image data files without requiring manual operator manipulation, thereby eliminating inconsistencies and reducing time loss while maintaining the ability to accommodate individual subject variations through algorithmic processing.
2Manufacturing precision
If manual trim line marking is performed by highly skilled orthotists, then accurate trim lines can be obtained, but the process requires extensive operator expertise and time
Solution Approach 1:
The system enables self-service by automatically generating accurate trim lines through computer algorithms without requiring highly skilled orthotists to manually mark them. The automated system processes the three-dimensional digital data and produces precise trim lines independently, eliminating the need for extensive operator expertise while maintaining manufacturing precision.
Solution Approach 2:
The patent uses digital copying and processing of the three-dimensional head shape data to generate trim lines. Instead of manual marking on physical models, the system creates digital representations and automatically determines trim line locations through algorithmic analysis, thereby achieving high accuracy without requiring skilled operators to interpret and mark physical models.
3Adaptability or versatility
If custom cranial remodeling devices are produced using manual methods, then flexibility to accommodate individual subjects is achieved, but productivity and efficiency are reduced
Solution Approach 1:
The system maintains adaptability to individual subjects by processing unique three-dimensional digital data for each patient's head shape. The automated system adjusts parameters such as reorientation angles, selected image portions, and trim line generation based on the specific characteristics of each subject's data, thereby preserving customization while dramatically improving productivity through automated processing.
Data Source
AI summary
A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.