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?