3D scanning can be used at multiple stages of the product development process. Scans are collected from target populations to analyze anthropometric size and shape variations. Representative 3D models are created based on scan data to aid in virtual and physical prototyping. Designs are evaluated virtually through fit analysis and finite element analysis before finalizing. The process allows iterative, data-driven optimization of product designs to match human diversity in an efficient manner.

1. 1
3D Scan-Based Design
in Product Development Process
Wonsup Lee, PhD
Researcher, Industrial Design Engineering, Delft University of Technology, The Netherlands
Ergonomics Design Consultant, Humanopia, Delft, The Netherlands

2. 2
3D Scanning in PD Process
Design
Planning
Data
Collection
Analysis
Design/
CAD
Proto-
typing
(Virtual)
Evaluation
Finalizing

3. 3
Data Collection
Design
Planning
Data
Collection
Analysis
Design/
CAD
Proto-
typing
(Virtual)
Evaluation
Finalizing

4. 4
3D Body Scanning
Artec hand-held scanner 3dMD scanner

5. 5
Ear Example
• Scanning of the ear including ear canal
Outside Inside Merged

6. 6
Skin Deformation Example
• Scanning of deformed skin through a glass panel

7. 7
3D Scan Datasets in My Research
• [Face] Korean Air Force pilot (n = 336)
• [Head/Full-body] CAESAR North American (n = 2,299)
• [Head] Dutch children (n = 302)
• [Ear] Korean and Caucasian (n = 326)
• [Torso] Size Korea elderly woman (n = 271)

8. 8
4D Scanning: Series of 3D Image Frames

9. 9
4D Scan Example
• Supporting analysis of motion, changes, and skin deformations

10. 10
Important Questions in 3D Data Collection
• Whom to scan? Which target people?
 Age
 Gender
 Ethnicity
 Anthropometric condition (e.g. height > 2 m)
• How many scans?
• Which body part?
• …

11. 11
Data Analysis & Design
Design
Planning
Data
Collection
Analysis
Design/
CAD
Proto-
typing
(Virtual)
Evaluation
Finalizing

12. 12
Anthropometry for Size Determination
Where to measure?
• 3D anthropometry: Measurements from 3D scans

13. 13
Body Size & Representative Models
1st
5th
95th
99th
1 head height 334 238.7 9.6 212.5 263.0 214.7 223.3 255.0 258.8
2 head breadth 335 160.9 6.4 123.5 180.5 146.4 151.4 171.2 175.3
3 head length 335 187.0 6.9 162.0 204.0 168.2 177.0 198.5 202.0
4 head circumference 335 564.5 13.5 516.5 604.5 533.4 543.2 587.2 596.2
5 face length 336 123.4 6.1 106.7 140.4 108.0 113.1 133.2 136.6
6 lower face length 336 69.1 4.5 57.5 83.6 58.6 61.8 76.3 79.4
7 sellion-bottom lip length 336 97.1 5.2 80.7 114.1 85.3 88.3 104.7 109.4
8 bottom lip-menton length 336 26.4 3.0 18.6 36.2 19.7 21.4 31.0 34.6
9 nasal bridge-menton length 336 109.1 5.5 93.2 124.3 95.8 99.8 117.7 120.8
10 nasal bridge-chin length 336 95.8 5.6 78.2 108.9 83.7 86.7 104.9 108.1
11 chin-menton length 336 13.3 2.5 4.9 20.6 7.9 9.5 17.6 19.1
12 nose length 336 54.3 3.4 43.2 62.2 46.6 48.6 60.3 61.9
13 nose protrusion 336 18.4 1.9 12.9 23.9 14.2 15.3 21.6 23.0
14 face width 336 154.8 6.4 132.4 171.5 138.6 144.0 164.2 168.2
15 chin width 336 130.3 8.6 105.4 156.7 112.5 116.5 144.6 150.8
16 minimum nasal bridge breadth 336 20.0 2.8 12.3 27.7 14.0 15.2 24.6 26.8
17 maximum nasal bridge breadth 336 30.5 2.8 22.3 37.7 24.2 25.6 35.3 36.7
18 nose width 336 37.6 2.7 30.3 45.8 31.8 33.4 42.4 43.8
19 lip width 336 49.1 3.8 38.5 58.2 40.7 42.6 55.5 57.4
20 bitragion-menton arc 336 313.7 16.2 269.0 361.1 273.5 284.1 339.1 347.3
21 bitragion-subnasale arc 336 283.0 12.9 234.9 319.6 252.1 263.1 304.5 312.1
22 bizygomatic-menton arc 336 304.8 14.5 261.3 339.6 267.0 277.8 327.6 336.2
No. Anthropometric dimension
Percentile
MaxMinSDMeann
5%ile 25%ile 75%ile 95%ile

14. 14
Making Physical Representative Forms

15. 15
Design based on Representative Models
Size Korea
elderly woman
(n = 270)
Representative sizes
(Digital models)
3D-printed models
Hip Protector
Design

16. 16
Using Size/Shape Variation for Design
lip
nose
Aligned at sellion
chin
Mid-sagittal cross-section curves
for designing one of critical part
in medical oxygen mask
Analysis of
nasal root part
Variation of nasal root
eye level
variation
variation

17. 17
Ear-Root Shape Variation for Ear Hook Design
Filtering
Searching
average curve
1. Design of the form
2. Adjustable range
(coverage)

18. 18
Virtual Evaluation
Design
Planning
Data
Collection
Analysis
Design/
CAD
Proto-
typing
(Virtual)
Evaluation
Finalizing

19. 19
Fit Analysis: Visual Check

20. 20
Fit Analysis: Fit Map Analysis
• Analysis of fit between 3D forms of human and product
hard fit around
forehead, nose,
and cheek
loose fit at side
⇒ Tightly wear for
fitting
⇒ Higher discomfort at
forehead, nose, cheek

21. 21
Virtual Fit Evaluation
• Efficiency: Automatic analysis of fit with hundreds of people
• Applicable to search optimal form of a product

22. 22
Virtual & Physical Evaluation
Prototyping
Iterative
Design
Adjustment
Virtual
Evaluation
Design/CAD
Physical
Evaluation
• Optimize design virtually
• Minimize cost/time for prototyping and
usability test

23. 23
Finite Element Analysis
• FEA can be used for contact pressure estimation

24. 24
Summary
• Roughly introduced the applicability of 3D scanning in PD process
• Design based on (1) anthropometric size & (2) shape variations
 Size Measurement  Product Design
 Size Measurement  Representative Models  Product Design
 Shape Variation  Product Design
• (3) Design  Virtual Evaluation iteration to find an optimized shape
Design
Planning
Data
Collection
Analysis
Design/
CAD
Proto-
typing
(Virtual)
Evaluation
Finalizing

25. 25
Thank you
Wonsup Lee, PhD (mcury83@gmail.com)