Geometry-Independent Native Mesh Design for Variable Brace Conformity
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Solution Overview
Problem
Current digital brace technology is imprecise and not customizable to fit the specific contours of an individual's body, leading to time-consuming and costly manufacturing for a specific individual, limiting its applicability to others.
Innovation Solution
A system and process for geometry-independent product design through native mesh surface selection and variable component conformity, utilizing a three-dimensional scan of human anatomy to create a modified treatment mesh, followed by profile curve tools, component placement, and pattern tools to generate a highly customized product design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom braces are manufactured to match the contours of a specific individual's body, then the fit precision and comfort are improved, but the manufacturing time and cost increase significantly
Solution Approach 1:
The system performs preliminary actions by capturing the patient's body geometry through 3D scanning before brace manufacturing. The scanned data is stored and processed to create a digital template that guides subsequent brace production, eliminating the need for time-consuming manual measurements and fittings during the manufacturing process.
Solution Approach 2:
The invention creates a digital copy of the patient's body surface through 3D scanning technology. This digital replica serves as a precise template for brace design and manufacturing, allowing the brace to be fabricated with exact contour matching without requiring repeated physical measurements or manual shaping during production.
2Manufacturing precision
If custom braces are manufactured for a specific individual, then the contour fit is improved, but the versatility and reusability deteriorate as they cannot be applied to others
Solution Approach 1:
The system achieves universality by creating adjustable brace designs based on digital body scans. The braces incorporate adjustable components and geometry-independent design features that allow a single brace design to be customized for different patients with varying body contours, enabling one brace type to serve multiple users while maintaining precise fit for each individual.
Solution Approach 2:
The invention utilizes parameter changes by allowing adjustment of brace geometry, size, and structural parameters after manufacturing. The digital design system stores multiple parameter sets that can be applied to the same brace design to accommodate different patient anatomies, enabling the same physical brace to be reconfigured for different users through parameter modification rather than complete remanufacturing.
3Ease of manufacture
If traditional digital brace technology is used, then the manufacturing process is simpler, but the customization precision and comfort deteriorate
Solution Approach 1:
The system replaces traditional mechanical measurement and fitting processes with digital 3D scanning and computational design. Instead of manual measurements, physical templates, and iterative fitting adjustments, the invention uses optical scanning to capture body geometry and algorithmic processing to generate precise brace designs, significantly improving customization precision while maintaining manufacturing efficiency through automated design generation.
Solution Approach 2:
The invention enables precise customization by allowing detailed modification of design parameters based on the digital body scan data. The system can adjust curvature, thickness, reinforcement locations, and other geometric parameters to precisely match the patient's anatomy, achieving high customization precision while the automated parameter adjustment maintains manufacturing simplicity through software-based design optimization.
Data Source
AI summary
A configuration enables variable component conformity to native mesh. Surface position and parametric adjustment parameters are received for an image mesh and projection parameters are identified for a component. Variable component conformity is initiated for RGB variables for object vertices. A control point location is placed on the image mesh and is paired with a centroid of a surface and equated to a first and second coordinate systems. Each coordinate system retains component vertices locations as a first set of coordinates. For each vertex, an RGB value is identified. Using the RGB value, a hybrid vertex location is calculated by equating coordinates from the first coordinate system with the coordinates from the second coordinate system and adjusting an offset value. A new set of coordinates is generated in the second coordinate system and mapped vertices are generated from the hybrid vertex location to generate an output for the component.