Prosthetic Limb Fairing Using Mirror Image Scanning
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Solution Overview
Problem
Existing prosthetic limbs lack symmetry with the human form, leading to an asymmetric appearance that can be perceived as a health shortcoming, and current solutions fail to provide a personalized and aesthetically pleasing option for amputees, as they are often made from disparate components and lack accurate dimensional representation of a human leg.
Innovation Solution
A prosthetic limb designed using computer-aided design (CAD) software and computer-controlled fabrication processes to create a symmetrical appearance matching the user's intact limb, with a removable fairing that allows for personalization and customization of the prosthetic's appearance, using optical scanning for precise measurements and combining mirror image data with mechanical components for comfort and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional prosthetic components (socket, pylon, foot) are used to create the prosthetic limb, then the prosthetic can be manufactured with functional components, but the appearance becomes asymmetric and does not match the human form
Solution Approach 1:
The prosthetic limb is divided into separate functional components (socket, pylon, foot) and a cosmetic fairing component. The fairing is designed as a separate aesthetic layer that can be customized independently from the functional components, allowing symmetry and appearance matching without redesigning the entire prosthetic system.
Solution Approach 2:
The fairing is designed to copy or mirror the appearance of the user's intact limb using optical scanning and mirror image generation. This allows the prosthetic to achieve symmetric appearance by replicating the geometry of the healthy limb rather than trying to make the functional components themselves symmetric.
2Shape
If a flesh colored foam cover is used to improve appearance, then the diameter becomes more uniform, but the representation is not accurate and can connote dead tissue
Solution Approach 1:
Instead of using generic foam covers, the fairing is created by optically scanning the user's intact limb and generating a precise digital mirror image. This copying process captures accurate dimensional data and surface geometry, ensuring the fairing matches the user's specific anatomy rather than using standardized foam shapes.
Solution Approach 2:
The fairing design process involves changing parameters from generic foam dimensions to customized dimensions derived from optical scanning data. The digital model allows precise control of surface curvature, diameter variations, and other geometric parameters to accurately represent the user's specific limb morphology.
3Ease of manufacture
If the socket, pylon and foot are custom fabricated from disparate manufacturers, then the prosthetic can be assembled with functional components, but the asymmetric appearance cannot be disguised
Solution Approach 1:
The prosthetic system is segmented into functional components (from various manufacturers) and a separate cosmetic fairing. This segmentation allows the functional components to be assembled from disparate sources while the fairing provides the symmetric appearance, solving the contradiction between ease of manufacture and aesthetic symmetry.
Solution Approach 2:
The fairing acts as an intermediary layer between the functional components and the external environment. It mediates the appearance by covering the asymmetric functional components and presenting a symmetric surface to observers, while allowing the functional components to remain independent and easily replaceable.
4Shape
If the prosthetic limb is designed to match the user's intact limb using optical scanning and mirror image data, then the appearance becomes symmetrical, but the customization and personalization options are limited
Solution Approach 1:
The fairing design system allows dynamic switching between different appearance modes. Users can choose to have the fairing match their intact limb for symmetry, or select from alternative designs for personalization. The digital modeling process enables flexible adjustment of geometric parameters to achieve either anatomical accuracy or aesthetic customization.
Solution Approach 2:
The fairing serves multiple functions: it provides symmetric appearance by matching the intact limb, allows personalization through alternative designs, and can be easily replaced or modified. The digital design system supports both anatomical copying and creative customization, making the fairing a multi-functional cosmetic component.
Data Source
AI summary
A prosthetic limb has an outer surface that is a mirror image of an intact limb. The intact limb is scanned and the surface data is manipulated to create a virtual mirror image. The end of the amputated limb is also scanned to obtain socket data. A virtual limb is designed using a computer program based upon the mirror image and end of the amputated limb data. The computer program is also used to design a removable fairing that provides color and texture to the prosthetic limb.