Custom Modular Braces 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 suboptimal fit and comfort for patients, particularly in cases requiring precise control and conformity to individual body shapes.
Innovation Solution
A process using photogrammetry to capture three-dimensional surface data of a patient's body, combined with CAD design and rapid prototyping, allows for the creation of custom modular braces and casts that accurately match the patient's anatomy, incorporating adjustable and removable sections for growth or healing stages, and incorporating ventilation and flexibility features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional off-the-shelf braces are used, then cost is reduced and availability is improved, but manufacturing precision and adaptability to individual body shapes deteriorate
Solution Approach 1:
The patent performs preliminary scanning and measurement of the patient's body to create a digital model before brace fabrication. This preliminary action captures precise anatomical data that guides subsequent custom manufacturing, ensuring both high precision and cost-effectiveness through digital planning
Solution Approach 2:
The patent creates a digital copy or replica of the patient's body surface through scanning technology. This digital model serves as a precise template for brace design and manufacturing, eliminating the need for physical molds while maintaining high conformability to individual body shapes
2Manufacturing precision
If custom braces are manufactured using traditional methods, then manufacturing precision is improved, but productivity and production time worsen
Solution Approach 1:
The patent replaces traditional mechanical measurement methods (manual measuring tapes, physical molds) with optical scanning and digital modeling systems. This substitution dramatically reduces production time while maintaining or improving manufacturing precision through automated data capture and computer-aided design
Solution Approach 2:
The patent transforms physical measurement parameters into digital data parameters through scanning. This parameter transformation enables rapid iteration, easier modification, and faster manufacturing while maintaining high precision, as digital parameters can be adjusted and transmitted electronically without physical re-measurement
3Strength
If hinged braces are used, then support and stability are improved, but device complexity and difficulty of operation worsen
Solution Approach 1:
The patent divides the brace into multiple segments or panels that can be independently adjusted and positioned. This segmentation allows the complex hinged structure to be broken down into manageable components, each providing specific support functions while simplifying overall assembly and adjustment procedures
Solution Approach 2:
The patent incorporates dynamic elements such as adjustable hinges and movable components that allow the brace to adapt to different positions and movements. These dynamic features provide enhanced support and stability while maintaining ease of operation through controlled adjustability rather than fixed rigid structures
4Ease of operation
If elastic braces are used, then ease of operation and comfort are improved, but manufacturing precision and control of motion worsen
Solution Approach 1:
The patent applies different material properties and structural characteristics to different regions of the brace. High-precision rigid sections provide motion control where needed, while more flexible elastic sections provide comfort and freedom of movement in other areas. This local differentiation resolves the contradiction between comfort and precision control
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 results in custom-fitted braces and casts that provide improved comfort, support, and hygiene, reducing the need for frequent replacements and minimizing patient discomfort and trauma, while also reducing production time and costs.
Implementation Method 1
A process using photogrammetry to capture three-dimensional surface data of a patient's body
Data Source
AI summary
A custom device and method for fabricating the custom device 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 a brace having an inner surface that corresponds to the contours of the body. The custom modular brace is fabricated as multiple pieces that are releasably coupled together and sequentially removed as the patient heals.