Customized Clavicle Protector via 3D Scanning and Additive Manufacturing
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Solution Overview
Problem
Existing protective devices often suffer from improper fit, limited range of motion, and discomfort due to their standard sizes, which can hinder their effectiveness in providing protection and promoting healing for specific body parts.
Innovation Solution
Customized protective devices are created using digital three-dimensional modeling and additive manufacturing, featuring contoured members with specific contact and non-contact portions to conform to individual anatomy, allowing for optimal protection and mobility while minimizing discomfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard off-the-shelf protective devices are used, then affordability and availability are improved, but fit accuracy and protection effectiveness deteriorate
Solution Approach 1:
The patent uses 3D scanning to create a digital copy of the patient's anatomy and then generates a customized protective device based on this digital model. This digital copying approach allows for precise replication of individual anatomical features while maintaining manufacturing efficiency through computer-controlled fabrication processes.
Solution Approach 2:
The patent transforms the manufacturing process by changing from traditional manual molding techniques to computer-controlled additive manufacturing or subtractive manufacturing. This parameter change in the manufacturing method enables both high precision customization and cost-effectiveness through automated production processes.
2Adaptability or versatility
If hand-molded protective devices are used, then customization is improved, but material constraints and molding limitations worsen
Solution Approach 1:
The patent replaces the manual mechanical molding process with a digital modeling and computer-controlled manufacturing system. The 3D scan data is processed through software to generate precise digital models, which are then manufactured using automated machinery. This substitution eliminates the material and geometry constraints inherent in manual hand-molding techniques.
Solution Approach 2:
The patent fundamentally changes the manufacturing parameters from manual control to computer-controlled precision manufacturing. This allows for greater freedom in material selection and geometric complexity while maintaining consistency and reducing human error in the manufacturing process.
3Adaptability or versatility
If plaster mold casting is used, then material variation and geometry flexibility are improved, but time consumption and cost worsen
Solution Approach 1:
The patent replaces the time-consuming plaster mold casting process with a direct digital modeling approach. The 3D scanning captures the anatomy in minutes, and the digital model is generated and manufactured through computer-controlled processes, eliminating the need for multiple plaster molds and manual casting steps.
Solution Approach 2:
The patent performs preliminary digital capture and modeling of the patient's anatomy before the actual device manufacturing. This preliminary digitalization step allows for rapid iteration and optimization of the device design without repeating time-consuming physical molding processes, thereby reducing overall production time.
4Reliability
If protective devices are made to fit tightly for protection, then protection effectiveness is improved, but range of motion and comfort worsen
Solution Approach 1:
The patent applies different levels of contouring and support to different regions of the protective device based on the patient's anatomical requirements. Areas requiring maximum protection receive tighter fitting and more structural support, while areas requiring mobility receive less restrictive designs. This localized differentiation allows the device to simultaneously provide effective protection and maintain range of motion.
Solution Approach 2:
The patent incorporates dynamic elements into the protective device design, such as adjustable components or flexible regions that can adapt to the patient's movements. This dynamic capability allows the device to maintain secure protection during stationary periods while accommodating range of motion requirements during activity, thereby balancing protection effectiveness with ease of operation.
Data Source
AI summary
A clavicle protective device may include a contoured member configured to cover at least a portion of the clavicle. The contoured member may have an inner surface configured to face the at least a portion of the clavicle and an outer surface configured to face away from the at least a portion of the clavicle. The contoured member may include a first contact portion, a second contact portion, and a bridge portion positioned between the first contact portion and the second contact portion. The first contact portion may be configured to contact the subject's body above the clavicle. The second contact portion may be configured to contact the subject's body below the clavicle. The bridge portion may be configured to be spaced apart from the subject's body when the first contact portion and the second contact portion contact the subject's body.