American Anaplastology Association 2007 Annual Conference Application of Digital Technologies for the Fabrication of Prosthetics Michael Raphael - Direct Dimensions, Inc. Paula Sauerborn - Center for Prosthetic Restoration, Inc.

Introduction Methods 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

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

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

accuracy

resolution

speed

cost

Arm-Based Laser Scanner accuracy resolution speed cost

accuracy

resolution

speed

cost

CMM-Based Laser Scanner accuracy resolution speed cost

accuracy

resolution

speed

cost

Scanners Cost Vs. Resolution cost resolution

Data Acquisition Process Initial Set-Up Calibration Part Preparation material color issues registration issues (marrying) Scanning Process time quality control part manipulation

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

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 PROCESS 8 Major Steps

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

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

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

accuracy

resolution

speed

cost

FDM Rapid Prototype accuracy resolution speed cost

accuracy

resolution

speed

cost

SLA Rapid Prototype accuracy resolution speed cost

accuracy

resolution

speed

cost

SLS Rapid Prototype accuracy resolution speed cost

accuracy

resolution

speed

cost

3-D Printing Rapid Prototype accuracy resolution speed cost

accuracy

resolution

speed

cost

Rapid Prototyping Cost Vs. Resolution resolution cost

Current RP Recommendation 3-D Printing lower cost machines cheaper raw materials acceptable resolution faster production limited training less hazardous Zprinters Thermojet Dimension Objet

lower cost machines

cheaper raw materials

acceptable resolution

faster production

limited training

less hazardous

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

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 Terms Point Cloud : dense group of XYZ 3D point values STL File : electronic format for triangulated data Polygonal : conversion of point cloud to triangles Triangulation : same as polygonal Decimation : reducing the number of triangles CMM : coordinate measuring machine Accuracy : closeness to the intended or nominal value Resolution : quantity of items per unit of area Rapid Prototype : computer-based layered manufacturing 3D 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

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 Special Limited Time Introductory Pricing 3-D Digital Scan and Rapid Prototype pricing starting at $250

Thank you for your time and interest QUESTIONS?