Prosthesis Socket Modeling With AR for Internal Anatomy Fit
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Solution Overview
Problem
Existing methods for manufacturing orthopedic products, such as prosthetic sockets, fail to adequately account for the internal structure and dynamic movements of the amputation stump, leading to suboptimal fit and comfort, and require time-consuming iterative adjustments.
Innovation Solution
A method that captures and displays body part data, including internal structure information, allows users to deform and mold the body part virtually, and generates production data for orthopedic products, incorporating these changes to create customized designs using augmented or virtual reality devices and 3D scanning technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plaster casting is used to create a negative mold, then low cost and ease of manual shaping are achieved, but the internal structure and dynamic movements of the amputation stump cannot be captured
Solution Approach 1:
The patent combines multiple data acquisition methods (optical scanning for external geometry, MRI/CT for internal structure, motion capture for dynamics) into a unified digital model that integrates all information about the amputation stump, resolving the contradiction between ease of manufacture and information loss by merging diverse data sources
Solution Approach 2:
The patent introduces a computer as an intermediary that processes and integrates data from multiple sources (scanners, imaging devices, motion capture systems) to create a comprehensive digital model, enabling the capture of internal structure information without requiring direct physical contact or complex manual procedures
2Speed
If optical scanning is used to measure the amputation stump, then external shape data is obtained quickly, but the stump cannot be deformed or moved during scanning
Solution Approach 1:
The patent transitions from static optical scanning to dynamic motion capture technology that records the amputation stump in various positions and states of movement, enabling the capture of deformed and dynamic states while maintaining high scanning speed through automated multi-camera systems
Solution Approach 2:
The patent performs preliminary actions by having the patient perform specific movements and deformations before the actual scanning process, allowing the system to capture a comprehensive range of states including deformed positions, which are then integrated into the final digital model
3Device complexity
If only external shape is considered in socket design, then the manufacturing process is simple, but individual requirements and internal characteristics cannot be incorporated
Solution Approach 1:
The patent applies local quality by using the comprehensive digital model to identify and address specific local characteristics of the amputation stump (such as bone prominences, soft tissue distribution, and pressure points) in the socket design, enabling precise customization without overwhelming complexity in the manufacturing process
Solution Approach 2:
The patent creates a precise digital copy (virtual model) of the amputation stump that includes internal structure and dynamic characteristics, allowing the design process to work with this accurate replica rather than the actual stump, thereby incorporating individual characteristics without significantly increasing manufacturing complexity
4Manufacturing precision
If iterative adjustments with test sockets are performed, then fit accuracy is improved, but time and resources are consumed
Solution Approach 1:
The patent performs preliminary actions by creating a comprehensive digital model that captures all relevant characteristics (external geometry, internal structure, dynamics) before the actual socket manufacturing, allowing the design to be optimized in silico and reducing or eliminating the need for iterative physical adjustments and test sockets
Solution Approach 2:
The patent implements feedback mechanisms where the digital model and simulation results provide immediate information about potential fit issues, allowing designers to make corrections before manufacturing, thereby reducing the need for time-consuming iterative adjustments with physical test sockets
Data Source
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Figure 3
AI summary
The invention relates to a method for manufacturing an orthopedic product for a body part of a patient, the method comprising the following steps: a) providing body-part data containing information about an internal structure of the body part, b) detecting a current line of vision from which a user of the method sees the body part, c) displaying the body part data from the current line of vision by means of the display device so that the user sees the body part and the body part data superimposed, d) generating production data for the orthopedic device on the basis of the displayed data and e) providing an orthopedic product manufactured on the basis of the production data.