Direct DICOM to G-Code Conversion for Medical 3D Printing

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Solution Overview

Problem

The existing methods for converting medical images into 3D printable G-Code instructions are time-consuming and result in the loss of anatomical information due to surface rendition and reslicing, limiting the efficiency of 3D printing from medical images.

Innovation Solution

A direct method that converts DICOM images into G-Code without intermediate triangularization and reslicing, using a computer program that processes images row-by-row to generate 3D printing instructions for each 2D slice, significantly reducing processing time and file size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If conventional surface rendition and reslicing methods are used to convert medical images to G-Code, then anatomical information can be preserved through surface modeling, but processing time increases significantly and file size increases

Engineering Contradiction:

Improveanatomical informationVSAvoidprocessing time

Core Design Contradiction:

Loss of informationVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the intermediate surface rendition (STL conversion) and reslicing steps from the conventional workflow. By directly converting DICOM image data to G-Code instructions, the method removes unnecessary processing stages that consume time and computational resources while preserving the essential anatomical information needed for 3D printing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a direct conversion algorithm as an intermediary process that translates DICOM image data directly into G-Code instructions without requiring surface modeling intermediates. This intermediary conversion method maintains anatomical fidelity while significantly reducing processing time by establishing a direct translation pathway between medical imaging format and 3D printing format.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of information

Engineering Contradiction:

Improveanatomical informationVSAvoidfile size

Core Design Contradiction:

Loss of informationVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies local quality optimization by generating G-Code instructions with varying detail levels appropriate for different regions of the anatomical structure. The direct conversion method allows for selective preservation of anatomical features based on their importance, reducing file size by eliminating redundant surface modeling data while maintaining critical anatomical information.

Inventive Principle:

Principle #3Local quality

3Loss of time

If direct conversion from DICOM to G-Code is implemented without intermediate steps, then processing time is reduced significantly, but complexity of the conversion algorithm increases

Engineering Contradiction:

Improveprocessing timeVSAvoidconversion algorithm complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical multi-step process (DICOM to STL to G-Code) with a direct algorithmic conversion system. The conversion algorithm processes DICOM image data and generates G-Code instructions through computational logic, eliminating the need for intermediate surface modeling operations and significantly reducing processing time despite increased algorithmic complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of time

If direct conversion from DICOM to G-Code is implemented without intermediate steps, then processing time is reduced significantly, but file size reduction is achieved

Engineering Contradiction:

Improveprocessing timeVSAvoidfile size

Core Design Contradiction:

Loss of timeVSLoss of substance

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the conventional approach by converting from the source format (DICOM) directly to the target format (G-Code) rather than converting through intermediate formats. This inversion of the conversion pathway eliminates redundant data transformations and produces more compact file outputs while maintaining processing efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11872764B2Three-dimensional printing from images

Publication Date: 2024.01.16 THE TRUSTEES OF THE UNIV OF PENNSYLVANIA

AI summary

Methods, systems, and computer readable media for 3D printing from images, e.g., medical images or images obtained using any appropriate volumetric imaging technology. In some examples, a method includes receiving, from a medical imaging device, a multi-dimensional image of a structure. The method includes, for each two dimensional (2D) slice of the multi-dimensional image, converting, row-by-row for each row of the 2D slice, voxels of the 2D slice into 3D printing instructions for the 2D slice. The method includes 3D printing, by controlling a 3D printing extruder, a physical model based on the structure by 3D printing, slice by slice, each 2D slice using the 3D printing instructions.