Custom Shell Seat Design Using 2D Sagittal Profile Extraction
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Solution Overview
Problem
Current methods for custom-making shell seats are inefficient, subjective, and costly due to reliance on 3D shape measurements, which are ambiguous and require multiple corrections, leading to suboptimal results and increased production time and cost.
Innovation Solution
A method using a two-dimensional sagittal profile to determine the shape of a shell seat, combined with computer-controlled programming to simplify and objectify the design process, reducing the need for extensive measurements and allowing for objective evaluation and minimalistic, comfortable seat design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If 3D shape measurements are taken using vacuum bag or plaster print, then the complete shape of the seat and back can be obtained, but the process becomes ambiguous, subjective, and requires multiple corrections
Solution Approach 1:
The patent extracts only the essential 2D sagittal profile information from the full 3D body shape, eliminating the need for complete 3D scanning. This is achieved by using a semi-flexible element that conforms to the body's sagittal contour, capturing only the critical profile data needed for shell seat design while discarding redundant lateral and depth information.
Solution Approach 2:
The patent transitions from 3D shape measurement to 2D profile measurement by projecting the three-dimensional body contours onto a two-dimensional sagittal plane. This dimensional reduction simplifies the measurement process while retaining the essential geometric information needed for shell seat construction, eliminating the ambiguity of 3D point cloud data.
2Manufacturing precision
If multiple corrections are made to the shell seat model, then the fit can be improved, but the production time and cost increase
Solution Approach 1:
The patent performs preliminary positioning and measurement actions using the semi-flexible element to capture the accurate 2D sagittal profile before shell seat fabrication begins. By establishing the correct profile data upfront through proper positioning of the measurement element, the need for subsequent corrective iterations is minimized or eliminated entirely.
Solution Approach 2:
The patent implements an objective feedback mechanism by using the captured 2D profile to computationally generate the shell seat model, allowing for verification and adjustment of the design based on measured data before production, rather than relying on subjective post-fabrication fitting and correction.
3Loss of information
If complete 3D measurements are taken, then comprehensive body data is obtained, but the measurement process becomes difficult and requires high-specialized persons
Solution Approach 1:
The patent extracts only the necessary sagittal profile information from the complete 3D body shape, eliminating the need for complex 3D scanning equipment and specialized operators. The semi-flexible element naturally conforms to the body's sagittal contour, providing sufficient measurement data without requiring expertise in 3D spatial mapping or point cloud processing.
4Adaptability or versatility
If additional separate measurements are taken for corrections, then the shell seat can be better customized, but the process becomes more expensive and time-consuming
Solution Approach 1:
The 2D sagittal profile measurement serves multiple functions simultaneously: it provides the primary shape data for shell seat design, enables computational modeling, and offers objective feedback for verification. This single measurement approach replaces multiple separate measurement procedures that would otherwise be needed for customization and correction.
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3b
AI summary
In a first aspect, the invention relates to a method for designing a personalized shell seat for a subject, the method comprising obtaining a two-dimensional sagittal profile of the seating surface of a seating device, in which the shape of the seating surface is adapted to the posture and/or body contours of a subject sitting onto the seating device, and the computer-controlled design of a three-dimensional shell seat model, at least based on said obtained two-dimensional profile. In a second aspect, the invention relates a computer-controlled program for designing a personalised shell seat for a subject, for supporting the method and in a third aspect, the invention relates to a personalised shell seat for a subject that is designed using the method.