Custom Brace Fabrication via Photogrammetry and CAD Design
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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 suboptimal fit, comfort, and control for individual patients.
Innovation Solution
A photogrammetry-based process that uses multiple cameras to capture detailed surface data of a patient's body, combined with CAD design and 3D fabrication, allows for the creation of custom braces and casts with precise fit, modular design, and adjustable features for improved comfort and hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual measurement and molding methods are used to fabricate custom braces, then the process can be performed with simple equipment, but the manufacturing precision and measurement accuracy are insufficient
Solution Approach 1:
The patent uses photogrammetry to create a digital 3D copy of the patient's body surface from multiple 2D photographs. This digital model serves as an accurate replica that can be measured and used for brace design without requiring complex physical measurement equipment or manual molding processes.
Solution Approach 2:
The patent replaces manual mechanical measurement and molding techniques with an optical measurement system. Multiple cameras capture images of reference points on the patient's body, and computational algorithms process these images to generate precise 3D coordinates, eliminating the need for complex mechanical measuring devices.
2Measurement precision
If photogrammetry with multiple cameras is used to capture detailed surface data, then the measurement precision and manufacturing precision are significantly improved, but the device complexity and process complexity increase
Solution Approach 1:
The patent divides the measurement task into multiple manageable components: placing reference points on the patient's body, capturing images from multiple cameras, detecting the reference points in each image, and computationally reconstructing the 3D model. This segmentation allows each component to be optimized independently while working together to achieve high precision.
3Manufacturing precision
If custom braces are made to fit each patient accurately, then the comfort and effectiveness are improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent performs preliminary actions by capturing photogrammetry data and creating the 3D body model before the actual brace manufacturing process. This allows the design and planning phases to be completed in advance with high precision, and the physical fabrication can then proceed more efficiently using the pre-prepared digital model as a guide.
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 enables the production of custom braces and casts that provide accurate, comfortable, and selectively flexible solutions, reducing the need for frequent replacements and minimizing patient discomfort and trauma during application and removal.
Implementation Method 1
A photogrammetry-based process that uses multiple cameras to capture detailed surface data of a patient's body
Data Source
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AI summary
A custom brace and method for fabricating the custom brace includes marking a body with reference points and/or other indicators. Multiple color or infrared photographs of the body from different angles are then obtained. The photographs are used to determine the topography data of the body and identify the locations of the markings. The topography data and markings are then used to design the custom brace.