DDI 3D Medical Prosthetics Presentation to AAA Conference, April 2007


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This PowerPoint presents the technologies for 3D imaging human facial and other body parts for the digital design and fabrication of cosmetically accurate prosthetics.

This was presented by Direct Dimensions at the April 2007 conference for then named American Anaplastology Association.

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DDI 3D Medical Prosthetics Presentation to AAA Conference, April 2007

  1. 1. 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.
  2. 2. Introduction Methods for Obtaining a Mirror Image Prosthetic Rapid Prototype
  3. 3. Outline of Presentation <ul><li>Acquisition of 3-D Digital Data </li></ul><ul><li>Computer Modeling of Data </li></ul><ul><li>Output via Rapid Prototyping </li></ul><ul><li>Case Studies </li></ul><ul><li>Applications to Clinical Practice </li></ul><ul><li>Summary of Advantages </li></ul>
  4. 5. Acquisition of 3-D Digital Data <ul><li>Laser Scanners: </li></ul><ul><ul><ul><ul><li>Minolta 3-D Camera </li></ul></ul></ul></ul><ul><ul><ul><ul><li>ScanSys (FaroArm/Perceptron) </li></ul></ul></ul></ul><ul><ul><ul><ul><li>CMM-Based Laser Scanner (Kreon) </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Full Body and Head Scanners </li></ul></ul></ul></ul><ul><ul><ul><ul><li>Hand-Held Scanners </li></ul></ul></ul></ul><ul><li>Contact Digitizers: </li></ul><ul><ul><ul><ul><li>CMM (coordinate measurement machine) </li></ul></ul></ul></ul><ul><ul><ul><ul><li>MicroScribe </li></ul></ul></ul></ul><ul><ul><ul><ul><li>FaroArm Portable CMM </li></ul></ul></ul></ul><ul><li>CT/MRI Scanners </li></ul>
  5. 6. Minolta 3-D Camera <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  6. 7. Arm-Based Laser Scanner <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  7. 8. CMM-Based Laser Scanner <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  8. 9. Scanners Cost Vs. Resolution cost resolution
  9. 10. Data Acquisition Process <ul><li>Initial Set-Up </li></ul><ul><li>Calibration </li></ul><ul><li>Part Preparation </li></ul><ul><ul><li>material color issues </li></ul></ul><ul><ul><li>registration issues (marrying) </li></ul></ul><ul><li>Scanning Process </li></ul><ul><ul><li>time </li></ul></ul><ul><ul><li>quality control </li></ul></ul><ul><ul><li>part manipulation </li></ul></ul>
  10. 11. Computer Modeling of Data <ul><li>Software </li></ul><ul><ul><ul><li>PolyWorks - Modeler </li></ul></ul></ul><ul><ul><ul><li>GeoMagic - Studio </li></ul></ul></ul><ul><ul><ul><li>CAD - SolidWorks/Imageware </li></ul></ul></ul><ul><ul><ul><li>Other - Mimics, SolidView </li></ul></ul></ul><ul><li>Freeform Virtual Sculpting System </li></ul><ul><li>Computer Hardware </li></ul><ul><li>Training and Skills </li></ul>
  11. 12. Computer Modeling of Data PolyWorks/Modeler
  12. 13. Data Modeling Process <ul><li>Import raw point clouds </li></ul><ul><li>Clean Data: remove outliers and filter </li></ul><ul><li>Align multiple point cloud scans </li></ul><ul><li>Validate Data: accuracy, density, completeness </li></ul><ul><li>Triangulate : make into polygonal STL file </li></ul><ul><li>Cap Model: define and create model limits </li></ul><ul><li>Mirror : identify mirror plane and mirror model </li></ul><ul><li>Decimate to desired resolution/file size </li></ul>PROCESS 8 Major Steps
  13. 14. Data Modeling Process: Import Step 1: Import raw point clouds
  14. 15. Data Modeling Process: Clean Step 2: Remove outliers and filter points
  15. 16. Data Modeling Process: Align Step 3: Align multiple point cloud scans
  16. 17. Data Modeling Process: Validate Step 4: Validate for density and completeness
  17. 18. Data Modeling Process: Triangulate Step 5: Triangulate into polygonal STL file
  18. 19. Data Modeling Process: Cap Step 6: Define model limits and create caps
  19. 20. Data Modeling Process: Mirror Step 7: Define mirror plane and mirror model
  20. 21. Data Modeling Process: Decimate Step 8: Decimate to desired resolution/file size
  21. 22. Output via Rapid Prototyping <ul><li>Definition </li></ul><ul><ul><li>a computer-controlled stream of a chemical or laser light that binds materials, layer by layer, into a solid object </li></ul></ul><ul><ul><li>computer-controlled additive layered mfg. </li></ul></ul><ul><ul><li>commonly referred to as “3-D printing” </li></ul></ul><ul><li>Processes: </li></ul><ul><ul><li>LOM - Layered Object Manufacturing </li></ul></ul><ul><ul><li>FDM - Fused Deposition Modeling </li></ul></ul><ul><ul><li>SLA - Stereolithography Apparatus </li></ul></ul><ul><ul><li>SLS - Selective Laser Sintering </li></ul></ul><ul><ul><li>3-D Printing </li></ul></ul>
  22. 23. LOM Rapid Prototype <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  23. 24. FDM Rapid Prototype <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  24. 25. SLA Rapid Prototype <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  25. 26. SLS Rapid Prototype <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  26. 27. 3-D Printing Rapid Prototype <ul><li>accuracy </li></ul><ul><li>resolution </li></ul><ul><li>speed </li></ul><ul><li>cost </li></ul>
  27. 28. Rapid Prototyping Cost Vs. Resolution resolution cost
  28. 29. Current RP Recommendation 3-D Printing <ul><li>lower cost machines </li></ul><ul><li>cheaper raw materials </li></ul><ul><li>acceptable resolution </li></ul><ul><li>faster production </li></ul><ul><li>limited training </li></ul><ul><li>less hazardous </li></ul>Zprinters Thermojet Dimension Objet
  29. 30. Case Study 1: Foot Prostheses
  30. 31. Case Study 2: Hand Prostheses
  31. 32. Case Study 3: Finger
  32. 33. Case Study 4: Partial Foot/Toe Prostheses
  33. 34. Case Study 5: Auricular Prosthesis
  34. 36. Major Advantages of 3-D Digital Technologies <ul><li>saves clinical lab time </li></ul><ul><li>increases productivity </li></ul><ul><li>should improve accuracy of mirror </li></ul><ul><li>improves quality control </li></ul><ul><li>allows more time for patient contact </li></ul><ul><li>available today at reasonable cost </li></ul>
  35. 37. 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
  36. 38. Other Applications <ul><li>Medical </li></ul><ul><ul><li>Facial Prosthesis </li></ul></ul><ul><ul><li>Surgical Templates and Models </li></ul></ul><ul><ul><li>Medical Implants </li></ul></ul><ul><ul><li>Forensic Analysis </li></ul></ul><ul><ul><li>Anthropometric Databases </li></ul></ul><ul><li>Historic Documentation and Archival </li></ul><ul><li>Art, Architecture, and Sculpture </li></ul>
  37. 43. Other Applications
  38. 44. AAA Conference Special Limited Time Introductory Pricing 3-D Digital Scan and Rapid Prototype pricing starting at $250
  39. 45. Thank you for your time and interest QUESTIONS?