Orthotic Device Models Using Simulated Patient Anatomy
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Solution Overview
Problem
Current methods for producing orthotic devices are slow, expensive, and limited in customizability, often providing one-size-fits-all solutions that do not optimally address individual patient needs, and are restricted to machining hard materials, which limits the range of characteristics such as flexibility and shock absorption.
Innovation Solution
A method involving image capture of a patient's body part using mobile devices, followed by derivation of physical measurements and generation of anatomy and orthotic model data, allowing for the production of custom orthotic devices with variable density and mechanical properties tailored to individual anatomy, using 3D printing technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional plaster cast, gait scanning, or laser scanning methods are used to capture plantar geometry, then orthotic device production is achieved, but the process becomes slow, expensive, and limited in customizability
Solution Approach 1:
The patent replaces traditional mechanical scanning systems (plaster casting, laser scanning, gait scanning) with a mobile imaging system using cameras to capture foot geometry. This substitution of mechanical measurement systems with optical imaging dramatically reduces data acquisition time and cost while enabling rapid orthotic device production.
Solution Approach 2:
The patent changes the fundamental measurement parameters from mechanical contact-based measurements to optical image-based measurements. By capturing multiple images from different angles and using image processing algorithms to extract geometric data, the system achieves rapid data acquisition without the time-consuming mechanical scanning processes.
2Ease of manufacture
If traditional methods produce orthotic inserts with standardized shapes from databases, then production is simplified, but the devices lack patient-specific customization and optimal treatment effectiveness
Solution Approach 1:
The patent applies local quality by creating orthotic devices with spatially varying properties. The system generates patient-specific 3D models that capture unique anatomical features, then uses these models to manufacture orthotics with localized density variations and region-specific mechanical properties, ensuring optimal treatment for each patient's specific condition rather than using standardized shapes.
Solution Approach 2:
The patent changes manufacturing parameters from standardized database shapes to patient-specific 3D printed structures. By using additive manufacturing with variable density control, the system can produce orthotics with customized mechanical properties (flexibility, shock absorption, weight distribution) tailored to each patient's anatomy and treatment needs.
3Strength
If subtractive machining approaches are used to produce orthotic inserts, then hard materials can be processed, but the range of characteristics (flexibility, shock absorption, weight) is limited
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive machining to additive manufacturing. This enables the production of orthotic inserts with variable density and complex internal structures that cannot be achieved through machining. The additive process allows for graded materials and spatially varying mechanical properties, dramatically expanding the range of flexibility, shock absorption, and weight characteristics available.
Solution Approach 2:
The patent employs composite material approaches through additive manufacturing, combining materials with different properties in single orthotic structures. The variable density 3D printing process creates composite-like structures with regions of different stiffness and material composition, enabling simultaneous optimization of strength, flexibility, and shock absorption in different areas of the orthotic device.
4Ease of operation
If mobile devices with cameras are used to capture images, then portable and accessible data collection is achieved, but accurate physical measurements must be derived from 2D images
Solution Approach 1:
The patent solves the 2D-to-3D measurement challenge by capturing multiple images from different angles and elevations. By collecting image data in three-dimensional space (multiple viewpoints) and using photogrammetric algorithms to reconstruct the 3D geometry, the system accurately derives physical measurements from 2D camera images, maintaining both portability and measurement precision.
Solution Approach 2:
The patent introduces computational algorithms as an intermediary between the 2D camera images and the final 3D measurements. Image processing and photogrammetry software serve as the mediator that extracts accurate geometric data from 2D images by analyzing multiple views, perspective relationships, and known reference dimensions, enabling precise measurements without direct contact measurement tools.
Data Source
AI summary
The present disclosure relates to systems and methods for generating orthotic device models using simulated patient anatomy. In one implementation, a method comprises receiving images of a body part of a patient; deriving physical measurements from the images; generating anatomy model data of the body part using the physical measurements; and generating orthotic model data based on the anatomy model data, the orthotic model data being representative of an orthotic device.