Post on 16-Apr-2017
American Anaplastology Association2007 Annual Conference
Application of Digital Technologies for the
Fabrication of ProstheticsMichael Raphael - Direct Dimensions, Inc.
Paula Sauerborn - Center for Prosthetic Restoration, Inc.
IntroductionMethods for Obtaining a Mirror
Image Prosthetic Rapid Prototype
Outline of Presentation• Acquisition of 3-D Digital Data• Computer Modeling of Data• Output via Rapid Prototyping• Case Studies• Applications to Clinical Practice• Summary of Advantages
Acquisition of 3-D Digital Data• Laser Scanners: • Minolta 3-D Camera• ScanSys (FaroArm/Perceptron)• CMM-Based Laser Scanner (Kreon)• Full Body and Head Scanners• Hand-Held Scanners
• Contact Digitizers: • CMM (coordinate measurement machine) • MicroScribe• FaroArm Portable CMM
• CT/MRI Scanners
Minolta 3-D Camera
• accuracy• resolution• speed• cost
Arm-Based Laser Scanner• accuracy• resolution• speed• cost
CMM-Based Laser Scanner
• accuracy• resolution• speed• cost
ScannersCost Vs. Resolutionco
st
resolution
Data Acquisition Process• Initial Set-Up• Calibration• Part Preparation
• material color issues• registration issues (marrying)
• Scanning Process• time• quality control• part manipulation
Computer Modeling of Data• Software
• PolyWorks - Modeler• GeoMagic - Studio• CAD - SolidWorks/Imageware• Other - Mimics, SolidView
• Freeform Virtual Sculpting System• Computer Hardware• Training and Skills
Computer Modeling of Data
PolyWorks/Modeler
Data Modeling Process• Import raw point clouds• Clean Data: remove outliers and filter• Align multiple point cloud scans• Validate Data: accuracy, density, completeness• Triangulate: make into polygonal STL file • Cap Model: define and create model limits• Mirror: identify mirror plane and mirror model• Decimate to desired resolution/file size
PROC
ESS
8 Major Steps
Data Modeling Process: Import
Step 1: Import raw point clouds
Data Modeling Process: Clean
Step 2: Remove outliers and filter points
Data Modeling Process: Align
Step 3: Align multiple point cloud scans
Data Modeling Process: Validate
Step 4: Validate for density and completeness
Data Modeling Process: Triangulate
Step 5: Triangulate into polygonal STL file
Data Modeling Process: Cap
Step 6: Define model limits and create caps
Data Modeling Process: Mirror
Step 7: Define mirror plane and mirror model
Data Modeling Process: Decimate
Step 8: Decimate to desired resolution/file size
Output via Rapid Prototyping• Definition
• a computer-controlled stream of a chemical or laser light that binds materials, layer by layer, into a solid object• computer-controlled additive layered mfg.• commonly referred to as “3-D printing”
• Processes:• LOM - Layered Object Manufacturing• FDM - Fused Deposition Modeling• SLA - Stereolithography Apparatus• SLS - Selective Laser Sintering• 3-D Printing
LOM Rapid Prototype
• accuracy• resolution• speed• cost
FDM Rapid Prototype
• accuracy• resolution• speed• cost
SLA Rapid Prototype
• accuracy• resolution• speed• cost
SLS Rapid Prototype
• accuracy• resolution• speed• cost
3-D Printing Rapid Prototype
• accuracy• resolution• speed• cost
Rapid PrototypingCost Vs. Resolution
resolution
cost
Current RP Recommendation3-D Printing
• lower cost machines• cheaper raw materials• acceptable resolution• faster production• limited training• less hazardous
ZprintersThermojetDimension
Objet
Case Study 1: Foot Prostheses
Case Study 2: Hand Prostheses
Case Study 3: Finger
Case Study 4: Partial Foot/Toe Prostheses
Case Study 5: Auricular Prosthesis
Major Advantages of 3-D Digital Technologies• saves clinical lab time
• increases productivity• should improve accuracy of mirror• improves quality control• allows more time for patient contact• available today at reasonable cost
Glossary of Select TermsPoint Cloud: dense group of XYZ 3D point valuesSTL File: electronic format for triangulated data Polygonal: conversion of point cloud to trianglesTriangulation: same as polygonalDecimation: reducing the number of trianglesCMM: coordinate measuring machineAccuracy: closeness to the intended or nominal valueResolution: quantity of items per unit of areaRapid Prototype: computer-based layered manufacturing3D Printing: office environment rapid prototype systems
Other Applications• Medical
• Facial Prosthesis• Surgical Templates and Models• Medical Implants• Forensic Analysis• Anthropometric Databases
• Historic Documentation and Archival• Art, Architecture, and Sculpture
Other Applications
AAA Conference SpecialLimited Time Introductory
Pricing
3-D Digital Scan and Rapid Prototype pricing starting at $250
Thank you for your time and interestQUESTIONS?