Custom-Fit Wearable Modeling for Biomechanical Motion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional custom fitting methods for wearable devices, such as braces and orthoses, are time-consuming, costly, and fail to accommodate natural biomechanical motion, leading to suboptimal fit and effectiveness.

Innovation Solution

A method involving three-dimensional scanning, curve mapping, and additive manufacturing to create custom-fit wearable devices, utilizing anatomical landmarks for precise fitting and incorporating flexibility and motion ranges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional custom fitting methods (plaster casting) are used, then wearable devices can be manufactured, but the process is time-consuming and costly

Engineering Contradiction:

Improvemanufacturing speedVSAvoidfitting time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent uses 3D scanning to create a digital copy of the patient's anatomical structure, replacing traditional physical plaster casting. This digital model can be stored, reproduced, and modified without additional time or material cost, significantly improving manufacturing efficiency while reducing fitting time.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical plaster casting process with digital 3D scanning and computer-aided design. This substitution eliminates the manual, time-consuming nature of traditional methods while maintaining the ability to create custom-fit devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If traditional custom fitting methods are used, then wearable devices can be manufactured, but they fail to accommodate natural biomechanical motion

Engineering Contradiction:

Improvebiomechanical motion accommodationVSAvoidfit precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent incorporates dynamic elements into the wearable device design by integrating joint axes and range of motion data into the 3D model. This allows the device to adapt to and accommodate natural biomechanical motion while maintaining precise fit through digital customization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies different properties to different regions of the wearable device based on the specific anatomical features and motion requirements of each body part. This localized customization ensures both precise fit and appropriate flexibility in different areas.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If traditional custom fitting methods are used, then wearable devices can be manufactured, but the process is costly

Engineering Contradiction:

Improvemanufacturing costVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent creates a universal digital workflow that can be applied to various types of wearable devices and anatomical regions. The 3D scanning and modeling process serves multiple functions: creating the base model, determining joint axes, calculating range of motion, and guiding manufacturing, thereby reducing overall costs while improving efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20260026955A1Methods of designing and manufacturing custom-fit wearable devices

Publication Date: 2026.01.29 XO ARMOR TECHNOLOGIES INC

AI summary

Methods and systems are disclosed for manufacturing a custom-fit wearable device. In general, the methods and systems include generating a three-dimensional model of a body portion, identifying one or more anatomical landmarks, and mapping a curve onto the model based at least in part on those landmarks to define a continuous surface. Thickness and an offset may be applied to the surface. The resulting model may then be used to control an additive manufacturing process to produce the custom-fit wearable device.