Custom Brace Design Using Photogrammetry and CAD

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Solution Overview

Problem

Traditional methods for designing and manufacturing custom braces and casts are labor-intensive, inaccurate, and limited in geometric complexity, leading to inefficiencies and poor fit, which can result in discomfort, skin breakdown, and increased morbidity, especially in pediatric and veterinary applications.

Innovation Solution

A photogrammetry-based process that uses multiple cameras to capture surface data from a patient's body, combined with markings for specific features, to create a precise CAD design for custom braces and casts, allowing for accurate measurement and virtual fitting, reducing the need for sedation and improving hygiene.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manual measurement and fabrication methods are used for custom braces and casts, then manufacturing flexibility and adaptability are maintained, but manufacturing precision and measurement accuracy deteriorate due to labor-intensive processes and limited geometric complexity

Engineering Contradiction:

Improvebrace fit accuracyVSAvoidfabrication process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical measurement methods with optical photogrammetry systems using multiple cameras to capture body surface geometry. This substitution enables precise digital modeling and CAD design, achieving superior manufacturing precision while automating the complex fabrication process through computer-controlled manufacturing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention transforms physical body measurements into digital parameters through photogrammetry, enabling precise control of brace geometry. By changing from analog manual measurement to digital parameter-based design, the system achieves both high precision and automated fabrication, resolving the contradiction between precision and process complexity.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If traditional casting materials and methods are used, then ease of manufacture is maintained, but the brace thickness and weight increase, reducing patient comfort

Engineering Contradiction:

Improvepatient comfortVSAvoidbrace weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent employs thin-shell construction principles in CAD design, creating braces with optimized thickness profiles. The precise digital modeling enables fabrication of thinner sections where structural integrity is maintained, reducing overall weight and improving patient comfort while preserving ease of manufacture through automated processes.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If frequent cast replacements are performed to accommodate patient growth or healing, then adaptability is maintained, but loss of time and increased morbidity occur due to repeated application and removal trauma

Engineering Contradiction:

Improvebrace adaptability to growthVSAvoidtime for replacement procedures

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The invention introduces adjustable and modular design elements into the brace structure, enabling dynamic adaptation to patient growth and healing without complete replacement. The CAD system facilitates design of braces with adjustable components that can be modified in situ, reducing replacement frequency and associated time loss and morbidity.

Inventive Principle:

Principle #15Dynamics

4Measurement precision

If traditional measurement methods are used for pediatric and veterinary patients, then ease of operation is maintained, but measurement precision deteriorates requiring sedation which increases morbidity

Engineering Contradiction:

Improvebody surface measurement accuracyVSAvoidsedation requirements

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent implements rapid photogrammetric scanning that captures complete body surface geometry in seconds, performing measurement acquisition before patient movement or sedation becomes necessary. This preliminary rapid capture enables precise measurements in awake pediatric and veterinary patients, eliminating the need for sedation and associated morbidity.

Inventive Principle:

Principle #10Preliminary action

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 method enables the creation of custom-fitted, thinner, stronger, and more comfortable braces and casts with improved accuracy, reducing the need for frequent replacements, minimizing trauma, and lowering costs by allowing for modular designs and easy adjustments as the patient grows or heals.

Implementation Method 1

A photogrammetry-based process that uses multiple cameras to capture surface data from a patient's body

Methodology Applied

Scientific EffectPhotogrammetry: Photogrammetry

Data Source

PatentUS10482187B2Custom braces, casts and devices and methods for designing and fabricating

Publication Date: 2019.11.19 3D SYSTEMS INC

AI summary

A custom brace and method for fabricating the custom brace includes marking a body with reference points and/or other indicators. Multiple images of the body from multiple angles are then obtained. The images are used to determine the contours of the body and the other markings are located and used to design the custom brace. Fenestrations can be added to the brace design. The custom brace can be fabricated with the fenestrations as a single piece structure or in multiple pieces that are assembled to complete the custom device.