Custom Protective Gear via 3D Body Scan and Additive Manufacturing

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Solution Overview

Problem

Current methods for manufacturing personalized protective equipment, such as shin guards, are time-consuming and limited in customization, as they only allow changes to the contact surface, not size or thickness, and do not effectively account for individual body measurements, particularly complex curves like the shin or bow of the leg.

Innovation Solution

A method involving body scans to create a wearer mesh model, allowing for the customization of protective equipment by selecting and manipulating the size, thickness, and shape of the gear using a smartphone with depth-sensing technology, followed by additive manufacturing to produce a shell and liner that fit the individual's body perfectly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional measurement methods are used for personalized equipment, then manufacturing can be performed, but the process is time-consuming and cannot capture complex body curves

Engineering Contradiction:

Improvebody measurement accuracyVSAvoidmeasurement time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement with automated 3D scanning technology. The scanning system captures complete body geometry including complex curves like shin contours and leg bows, eliminating the need for manual tape measures and form fitting processes while significantly reducing measurement time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a digital 3D copy of the wearer's body geometry through scanning. This digital model serves as a precise template for manufacturing customized equipment, allowing repeated use and modification without physical remeasurement, thus reducing time while maintaining high measurement precision.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If current customization processes are used, then contact surface changes are allowed, but size and thickness modifications are not permitted

Engineering Contradiction:

Improvecustomization optionsVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent implements a dynamic customization system where the 3D body scan serves as a base model that can be dynamically modified in multiple dimensions. Users can adjust size, thickness, shape, and contact surface properties independently, and the system automatically updates the manufacturing specifications, making complex multi-parameter customization manageable.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent divides the customization process into separate adjustable parameters (size, thickness, shape, contact surface). Each parameter can be modified independently through the user interface, and the system handles the complexity of coordinating these changes across different equipment components, simplifying the manufacturing process.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If standardized equipment is manufactured, then production is simple, but individual body fit and protection are compromised

Engineering Contradiction:

Improveequipment fit precisionVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent performs the 3D body scanning and digital modeling as a preliminary action before manufacturing. By capturing the complete body geometry and creating a personalized digital twin in advance, the system prepares all customization parameters ahead of time, allowing rapid manufacturing without compromising fit precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses parameter-based customization where the 3D scan provides base dimensions, and the system automatically generates manufacturing specifications by adjusting parameters such as thickness, size, and shape. This approach maintains high manufacturing precision through automated parameter calculation while enabling fast production through digital manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

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

Enables rapid, unique manufacturing of customized protective equipment that fits individual body shapes and sizes, ensuring optimal protection while minimizing production defects and improving user comfort.

Implementation Method 1

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Data Source

PatentUS20220400795A1Methods for manufacturing individualized protective gear from scan and resulting products

Publication Date: 2022.12.22 AUBURN UNIVERSITY

AI summary

A method for manufacturing individualized protective gear such as pads based on a scan, and the resulting pads, are disclosed herein. A garment comprising a pocket with a visibly defined border is selected. A wearer dons the garment. A scan is taken of at least a portion of the garment over the wearer's body at the location where the pocket is disposed over the wearer's body. The scan is converted to a mesh model. The mesh model is used to define a first surface of the equipment configured to form to the wearer's body at the location where the pocket is disposed over the wearer's body and a second surface offset from the first surface. The model may be checked to identify production defects, which, if present, are removed. The equipment may be manufactured using additive printing technology.