Strain Sensor Orthosis for Body Geometry Capture

Solution Overview

Problem

The traditional method of plaster casting for manufacturing orthotic products is time and resource consuming, and direct optical body scanning is inefficient, especially for children and individuals with neurological or neuromuscular conditions, due to the need for stillness and the interference of healthcare practitioners' hands during scanning.

Innovation Solution

A method using a stretchable material with embedded strain sensors applied to a body part to detect stretching and deformation, coupled with a computing device to process sensor data and determine the three-dimensional shape of the body part, allowing for the design and fabrication of customized orthotic products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If direct optical body scanning is used to capture body surface geometry, then three-dimensional data set can be generated, but the method is inefficient and limited for children and patients with neurological conditions who cannot remain still

Engineering Contradiction:

Improvebody surface geometry captureVSAvoidpatient stillness requirement

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces the optical scanning system with a mechanical sensing system. Strain sensors are embedded in a flexible article that is wrapped around the body part, converting the optical measurement problem into a mechanical deformation measurement problem. The sensors detect strain caused by wrapping the article around the body, eliminating the need for optical scanning and patient stillness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The flexible article with embedded strain sensors acts as an intermediary between the body part and the measurement system. Instead of directly scanning the body surface, the article is wrapped around the body part and the strain sensors measure the deformation of the article itself, which indirectly provides information about the body part's geometry.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If healthcare practitioner applies force to support and correct anatomical body structures during scanning, then proper positioning and correction can be achieved, but the practitioner's hands interfere with and block the body-part scan

Engineering Contradiction:

Improveanatomical structure positioningVSAvoidscan data accuracy

Core Design Contradiction:

Manufacturing precisionVSLoss of information

Solution Approach 1:

The patent replaces the optical scanning system with a mechanical sensing system. Strain sensors are embedded in a flexible article that is wrapped around the body part, converting the optical measurement problem into a mechanical deformation measurement problem. The sensors detect strain caused by wrapping the article around the body, eliminating the need for optical scanning and patient stillness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The flexible article with embedded strain sensors acts as an intermediary between the body part and the measurement system. Instead of directly scanning the body surface, the article is wrapped around the body part and the strain sensors measure the deformation of the article itself, which indirectly provides information about the body part's geometry.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If extensive post-processing is performed to discriminate between patient's body and practitioner's hands in scan data, then accurate body geometry can be extracted, but time and computational resources are consumed

Engineering Contradiction:

Improvebody geometry extractionVSAvoidpost-processing time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the optical scanning system with a mechanical sensing system. Strain sensors are embedded in a flexible article that is wrapped around the body part, converting the optical measurement problem into a mechanical deformation measurement problem. The sensors detect strain caused by wrapping the article around the body, eliminating the need for optical scanning and patient stillness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The flexible article with embedded strain sensors acts as an intermediary between the body part and the measurement system. Instead of directly scanning the body surface, the article is wrapped around the body part and the strain sensors measure the deformation of the article itself, which indirectly provides information about the body part's geometry.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If traditional plaster casting method is used to manufacture orthoses, then custom orthotic products can be created, but the process is time and resource consuming

Engineering Contradiction:

Improvecustom orthotic fabricationVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces the optical scanning system with a mechanical sensing system. Strain sensors are embedded in a flexible article that is wrapped around the body part, converting the optical measurement problem into a mechanical deformation measurement problem. The sensors detect strain caused by wrapping the article around the body, eliminating the need for optical scanning and patient stillness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The flexible article with embedded strain sensors acts as an intermediary between the body part and the measurement system. Instead of directly scanning the body surface, the article is wrapped around the body part and the strain sensors measure the deformation of the article itself, which indirectly provides information about the body part's geometry.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables efficient and accurate capture of body part geometry and applied forces, facilitating the creation of customized orthotic products without the limitations of traditional scanning methods, improving treatment outcomes and reducing the need for extensive post-processing.

Implementation Method 1

a plurality of strain sensors positioned in contact with the material such that stretching of the material is detectable by the sensors

Methodology Applied

Scientific EffectStrain detection: Deformation

Data Source

PatentEP4027877B1Fabrication of custom orthosis

Publication Date: 2025.04.23 JOHN FLORENCE LTD

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AI summary

The invention provides an apparatus for use in determining the three-dimensional shape of an object, which apparatus comprises: an article, comprising a stretchable material, and a plurality of strain sensors positioned in contact with the material such that stretching of the material is detectable by the sensors; a computing device operatively coupled to the article and configured to receive output data from the sensors and to process the data to determine the three dimensional shape of the object. The invention also provides a method for providing a customized orthotic product using the apparatus.