Mold Surface Edge Flare Generation for Prosthetic Appliances
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Solution Overview
Problem
Existing methods for producing prostheses and orthoses often result in incorrectly positioned or shaped flared edges due to manual attachment of protrusions, leading to operator error and suboptimal appliance fit.
Innovation Solution
A method and apparatus that identify points representing an intended edge on a mold surface, adjust coordinates to alter the shape of regions on either side of the edge, and store the modified surface representation to produce a computer-aided manufacturing instruction set for precise edge formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If protrusions are manually attached to the three-dimensional reproduction to flare edges, then edge flaring can be achieved, but operator error occurs resulting in incorrectly positioned or shaped flares
Solution Approach 1:
The patent replaces the manual mechanical process of attaching protrusions with a computer-aided design and computer-aided manufacturing system. The system uses software to automatically generate the flared edge geometry and controls a carving machine to precisely carve the flared edges directly from the three-dimensional reproduction, eliminating manual attachment operations and associated operator errors
Solution Approach 2:
The system enables self-service by allowing the computer-aided design software to automatically calculate and generate the optimal flare geometry based on the imported three-dimensional surface data. The carve instructions are automatically generated from the digital model, making the process self-contained and eliminating reliance on manual operator skill for positioning and shaping flares
2Productivity
If manual methods are used to attach protrusions for edge flaring, then some edge modification capability is provided, but the process is time-consuming and subject to human error
Solution Approach 1:
The patent replaces time-consuming manual attachment operations with automated computer-aided manufacturing. The system imports three-dimensional surface data, generates flared edge geometry through software algorithms, and controls a carving machine to precisely carve the edges, dramatically reducing production time while improving consistency
Solution Approach 2:
The system performs preliminary action by pre-calculating and pre-visualizing the flared edge geometry in the computer-aided design environment before manufacturing. The digital model allows operators to review and adjust the flare design before committing to the physical carving process, preventing errors and reducing rework time
Data Source
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AI summary
A method, apparatus, media and signals for producing a representation of a mold for forming an appliance for a living body is disclosed. The method involves identifying points representing a line corresponding to an intended edge of the appliance on a surface of the mold, the surface being defined by an input plurality of points representing a general shape of the mold. The method also involves identifying regions extending along the surface on opposite sides of the line, adjusting at least one coordinate of at least one of the input plurality of points that falls within at least one of the regions to alter the shape of the surface in the at least one region to produce a modified surface representation, and storing the modified surface representation in a computer memory to produce a modified representation of the mold.