3D-Printed Ocular Prosthesis Modeling for Remote Custom Fitting
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Solution Overview
Problem
Existing ocular prostheses require time-consuming and expensive mold production, lack repeatability, and necessitate manual adjustments, which are cumbersome and often inaccurate, especially for patients with limited mobility or during pandemics, and do not allow for remote fabrication.
Innovation Solution
A method involving direct or indirect orbital scanning to create a digital model, followed by manual or automatic modeling, 3D printing with biocompatible materials, and applying graphics or painting to produce customizable ocular prostheses, allowing remote fabrication and quick modifications without repeating the entire process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mold production method is used, then ocular prosthesis can be manufactured, but the process is time-consuming and expensive
Solution Approach 1:
The patent changes the manufacturing approach from traditional mold-based subtraction or casting methods to additive manufacturing (3D printing). This parameter change in the manufacturing process enables direct fabrication of the prosthesis from digital models, eliminating mold production steps and significantly reducing both time and cost while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the mechanical mold-making system with a digital modeling and additive manufacturing system. The physical mold production process is substituted by computer-aided design (CAD) modeling followed by layer-by-layer 3D printing, which eliminates the need for creating and maintaining physical molds while improving productivity and reducing costs.
2Manufacturing precision
If manual adjustments are made to fit the prosthesis, then customization is achieved, but the process is cumbersome and inaccurate
Solution Approach 1:
The patent performs preliminary digital modeling and simulation before actual manufacturing. The prosthesis is designed and fitted virtually in the digital domain using patient-specific anatomical data from scanning, allowing precise customization and fit optimization before physical production. This preliminary digital action eliminates the need for cumbersome manual adjustments after manufacturing.
Solution Approach 2:
The patent creates an accurate digital copy of the patient's orbital anatomy through scanning and 3D modeling. This digital replica serves as the basis for designing the custom prosthesis, ensuring precise fit and customization without requiring manual measurement and adjustment procedures. The digital copy can be stored and reused for future modifications or replacements.
3Adaptability or versatility
If patients with limited mobility visit the clinic for prosthesis fabrication, then customization is possible, but accessibility is reduced
Solution Approach 1:
The patent introduces digital technology as an intermediary between the patient and the prosthesis manufacturing process. Patient-specific data is collected through scanning (either directly at the clinic or remotely), converted into digital models, and used to manufacture the prosthesis. This digital intermediary enables remote fabrication capabilities, allowing patients with limited mobility to receive customized prostheses without requiring repeated clinic visits.
Solution Approach 2:
The patent extracts the essential customization data from the patient through scanning and creates a complete digital model that can be used for manufacturing without requiring the patient's physical presence during the fabrication process. The critical anatomical information is extracted and stored digitally, enabling the manufacturing process to proceed independently of patient availability.
4Reliability
If molds are produced for each patient, then customization is achieved, but storage space and durability become issues
Solution Approach 1:
The patent replaces physical molds with digital models. Instead of creating and storing physical mold sets for each patient, the system creates accurate digital replicas of the patient's anatomy and stores these as digital files. These digital copies can be stored indefinitely without degradation, require minimal storage space, and can be easily reproduced or modified as needed, eliminating the durability and storage issues associated with physical molds.
Solution Approach 2:
The patent eliminates the need to maintain and store physical molds by using digital models that can be preserved indefinitely. The digital models serve as permanent templates that can be recovered and reused for manufacturing additional prostheses or creating modifications, replacing the traditional approach of maintaining physical mold inventories that occupy storage space and deteriorate over time.
Data Source
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AI summary
A method of fabrication of an ocular prosthesis including the following steps: a) making a geometric model of the eye socket through direct orbital scanning with an orbital scanner or indirectly by scanning an impression or cast of the eye socket; b) modifying of the obtained scan by manual or automatic modeling with use of a spatial modeling software; c) determining the geometric axis parallel to the axis of vision of the other eye or determining the axis in the case of making bi-ocular prostheses; d) completing a digital model of the prosthesis with use of geometric model of the eye, its modifications made with use of a spatial modeling software, and geometric axis; e) making a proper prosthesis from a biocompatible material with use of 3D printing according to the digital model of the prosthesis; f) smoothing and finishing the surface of the prosthesis; g) applying graphics of the sclera, blood vessels and iris on the prosthesis; h) securing the surface of the manufactured prosthesis (1) or a part thereof with a biocompatible varnish.