Undetectable Geometric Calibration Patterns for Multi-Camera Foot Scanning
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Solution Overview
Problem
Existing technologies for producing customized orthotic devices are limited in their ability to accurately capture three-dimensional foot models and pressure data, leading to suboptimal customization and comfort.
Innovation Solution
A scanning device with a support base, undetectable calibration pattern, and multiple cameras around its perimeter, combined with a pressure panel, captures high-definition images and pressure data to generate a three-dimensional reconstruction of the foot, using infrared-detectable patterns for calibration and pressure sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing and injection molding are used to produce orthotic devices, then manufacturing processes are well-established, but customization precision and fit accuracy are limited
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (subtractive manufacturing and injection molding) with additive manufacturing technology. This substitution enables precise customization of orthotic devices by building them layer-by-layer based on 3D foot scans, achieving superior fit accuracy while maintaining manufacturing feasibility through automated additive processes
Solution Approach 2:
The patent creates accurate digital 3D copies of the patient's foot anatomy through scanning and photogrammetry. These digital models serve as precise templates for manufacturing custom orthotic devices, ensuring that each device is an exact replica of the patient's specific anatomical requirements, thereby improving customization precision
2Measurement precision
If pressure sensing or imaging techniques are used to compute three-dimensional foot models, then customization capability is improved, but measurement precision and data accuracy are insufficient
Solution Approach 1:
The patent divides the foot scanning process into multiple independent camera views positioned around the foot. Each camera captures images from a specific angle, and the system segments the overall measurement task into multiple partial observations. These segmented views are then integrated through photogrammetry algorithms to reconstruct a complete and accurate 3D foot model, improving measurement precision while managing system complexity through modular camera arrangements
Solution Approach 2:
The patent introduces a calibration pattern as an intermediary element between the cameras and the foot. This pattern provides known reference points that enable precise calibration of camera positions and orientations. By using this intermediary calibration target, the system achieves accurate 3D reconstruction without requiring complex direct measurement, thereby improving measurement precision while keeping the scanning system manageable
3Measurement precision
If multiple cameras are distributed around the support base to capture the calibration pattern, then calibration accuracy is improved, but device complexity increases
Solution Approach 1:
The patent positions multiple cameras at equidistant locations around the circular support base, creating an equipotential geometric arrangement. Each camera is placed at the same radial distance from the center, ensuring uniform calibration conditions for all viewing angles. This symmetrical positioning simplifies the calibration process by providing consistent geometric relationships, improving calibration accuracy while reducing the complexity of precise asymmetric positioning
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
Enables precise customization of orthotic devices by generating accurate three-dimensional foot models and pressure maps, improving comfort and fit.
Implementation Method 1
a calibration pattern disposed on the upper surface and undetectable or substantially undetectable by wavelengths in the visible spectrum
Implementation Method 2
a plurality of cameras distributed around an outer perimeter of the support base and substantially oriented toward a center of the support base to capture the calibration pattern
Implementation Method 3
pressure panel comprises a plurality of pressure sensors arranged in a planar configuration. each of the plurality of pressure sensors, when the pressure panel is activated, are configured to generate signals representative of underfoot pressure
Data Source
AI summary
Embodiments of the present disclosure relate to a scanning device comprising a support base, a calibration pattern disposed on an upper surface of the support base, and a plurality of cameras distributed around an outer perimeter of the support base. In at least one embodiment, the calibration pattern is undetectable or substantially undetectable to the human eye.