Orthosis Modeling from Low-Resolution Body Scans
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Solution Overview
Problem
The traditional methods for creating orthoses are labor-intensive and prone to errors due to the need for accurate casting, and existing digital modeling methods are costly and limit design freedom by requiring precise landmark measurement.
Innovation Solution
A method using a statistical shape model that correlates measurement data from relatively inexpensive and low-resolution scans to create an accurate 3-D model of a body part, allowing for high-quality orthosis production with simple measuring equipment and extensive design freedom, incorporating anatomical and biomechanical zones for specific properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional plaster casting method is used to make orthosis, then the orthosis can be customized to fit the body part, but the process is labor-intensive and prone to errors
Solution Approach 1:
The patent replaces the traditional mechanical plaster casting process with a digital scanning and modeling system. A scanner captures the body part geometry, and software automatically generates the orthosis design, eliminating manual casting operations and reducing human error while maintaining customization accuracy.
Solution Approach 2:
The patent creates a digital copy (3D scan) of the body part instead of using physical plaster casting. This digital model serves as the basis for orthosis design and manufacturing, allowing for precise replication and modification without the errors associated with manual casting processes.
2Measurement precision
If expensive 3-D scanners are used to measure the body part, then accurate measurement data can be obtained, but the cost increases significantly
Solution Approach 1:
The patent employs lower-cost scanning technology that may have reduced individual precision but compensates through statistical processing. Multiple scans from different angles or devices are processed together to achieve accurate results, making the system economically viable while maintaining measurement quality.
Solution Approach 2:
The patent develops a universal statistical shape model that can work with various scanning devices and measurement methods. This model serves multiple functions: it can process data from different scan types, accommodate varying measurement precisions, and generate accurate orthosis designs regardless of the specific scanning equipment used.
3Ease of manufacture
If digital modeling with predetermined landmarks is used, then the orthosis can be designed digitally, but the design freedom is limited and error-proneness increases
Solution Approach 1:
The patent uses statistical shape models that allow continuous variation of geometric parameters rather than being constrained to predetermined landmark positions. This enables smooth, flexible modifications to the orthosis design while maintaining anatomical accuracy, significantly increasing design freedom without sacrificing manufacturing ease.
Solution Approach 2:
The patent implements a dynamic modeling approach where the orthosis design can be continuously adjusted based on the statistical shape model. The system allows for flexible modification of design parameters while maintaining the underlying anatomical relationships, enabling adaptability without increasing complexity.
4Device complexity
If simple measuring equipment is used to scan the body part, then the cost and complexity are reduced, but the measurement accuracy and resolution are insufficient
Solution Approach 1:
The patent introduces a statistical shape model as an intermediary between the simple scan data and the final orthosis design. This model fills in gaps and refines details from low-resolution scans by comparing the scan against a database of known anatomical variations, effectively enhancing measurement precision without requiring complex scanning equipment.
Solution Approach 2:
The patent performs preliminary processing of scan data by comparing it against pre-established statistical shape models. This preliminary action allows the system to compensate for low measurement resolution by using prior knowledge of normal anatomical variations, enabling accurate orthosis design even with simple measuring equipment.
Data Source
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AI summary
Method for making an orthosis of a body part of a person, wherein the method comprises of: - measuring the body part with a shape and in a pose in order to obtain measurement data of the body part; - correlating the measurement data of the body part to a predetermined statistical shape model of a corresponding reference body part in order to calculate parameters of the statistical shape model; - digitally forming an orthosis model on the basis of the statistical shape model with the known parameters; - producing the orthosis via a CAD/CAM system on the basis of the digitally formed orthosis model.