creating a 3d imaging system - researchresearch.vuse.vanderbilt.edu/srdesign/2005/group11... · •...
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Sole Supports is a privately owned and operated custom foot orthoticcompany located in Lyles, TN. They have a large market in podiatrists’offices across the world, which would increase if they could decreaseshipping time and costs while enlarging the manufacturing facilities. Thedesign team put together a solution in which doctors can scan a foamimpression of the customer’s foot and email it to Sole Supports. SoleSupports will use a computer program to extract x, y, z coordinates, scale toreal-world dimensions, and mill out an identical foam copy. This will saveSole Supports more than $460,000 in shipping per year and free up storagespace so that they can double manufacturing space, thus doubling theirprofits. Additionally, they will be able to expand into interested overseasmarkets because of eliminated inbound shipping costs and time.
ABSTRACTABSTRACT
Creating a 3D Imaging SystemBrad Boldizar1, Aubrey McKelvey1, Mackenzie Thomas1
Advised by: Dr. Paul King1, Dr. Ed Glaser2, and Matt Moore2
1Vanderbilt University Department of Biomedical Engineering, Nashville, TN, 2Sole Supports Inc., Lyles, TN
ReferencesReferences1. "Sole Supports Incorporated." 2006. Sole Supports, Inc.. <http://www.solesupports.com/>.2. King, Paul H. and Richard C. Fries. Design of Biomedical Devices and Systems. New York: Marcel
Dekker, 2003.3. "REI.com: Outdoor Gear & Clothing for Camping, Hiking, Backpacking and More!" 2006.
<http://gallery.rei.com>.4. "Modeling tools for designers." 2005. <http://www.rhino3d.com>.
Sole Supports aims to “produce the most functional custom foot orthotic…in order to prevent, reverse, or comfortably manage many common foot,lower extremity and spine pain syndromes, deformities and functionaldeficiencies.” Many over-the-counter varieties of orthotic insoles do notwork well for people because they overlook the fact that everyone’s archesare different. Sole Supports aims to fill this void in modern foot care.
WHAT SOLE SUPPORTS DOESWHAT SOLE SUPPORTS DOES
There are several objectives that we wanted to achieve with acomputer program. These include extracting the x, y, and z-intensityinformation from the scanned picture, putting these points into a columnarformat, and scaling these x, y, and z-intensity points into real-worlddimensions. To scale the points, we determined the number of pixels inone millimeter and used a simple linear equation to convert pixel positionto millimeters.
We began the project with the intention of using a LabViewenvironment to do this, but discovered that programming it in Pythonwould be simpler and more cost-effective (freeware). Our results fromPython gave us an error within the acceptable range of 2 mm.
SOFTWARE AND SCALINGSOFTWARE AND SCALING
• Make plastic apparatus on which doctors can place the foam block andprotect it from ambient light.
• Possibly try to find a less expensive scanner with an extra-long scanbed to make the apparatus more cost efficient for doctors’ offices.
• Sole Supports will eventually need to purchase new equipment, suchas a faster 3D milling machine and computers devoted to electronicstorage of data.
FUTURE PLANSFUTURE PLANS
IMPORTANCE OF ARCH STRUCTUREIMPORTANCE OF ARCH STRUCTURE
OUR GOALSOUR GOALS
1. Reduce excessive shipping time and cost.
2. Open up storage space for more room to manufacture.
Our Goals
Doctor seespatient in
office
Sole Supports sends foamblocks to participating doctors
Doctorimprintspatient’sfoot infoam
Doctor sends imprinted foamblocks back to Sole Supports
SoleSupports
checks forshippingdamage
SoleSupportscontinues
making theactual insole
Sole Supports sends more foamto the doctor for re-imprinting
Doctor callspatient back
in for re-imprinting
Doctor sends foam blocksback to Sole Supports
Sole Supports sends theinsoles to the doctor’s office
Doctors fitthe patient
with thenew custom
insoles
Sole Supportskeeps plaster
molds ofpatient’s feet
for 6+mo
COST ANALYSISCOST ANALYSISSole Supports can gain a financial return on investment (ROI) in a coupleof different ways:1. If we can eliminate shipping costs from the doctors’ offices to Sole
Supports, approximately $8-$16 per pair of insoles will be savedevery day. This amounts to ~$1280-$2560 per day saved onshipping, or more than $460,000 saved per year on shippingalone, not to mention the time savings.
2. Currently, Sole Supports uses a manufacturing space that is 10,000square feet. The storage facility is equal in size to the currentmanufacturing space, and if Sole Supports can convert the currentstorage space to more manufacturing room, they can double theirprofit, which is currently about $400 per square foot.
POSSIBLE SOLUTIONS ANDPOSSIBLE SOLUTIONS ANDCHOSEN METHODCHOSEN METHOD
Two potential methods were more closely evaluated:1. Two-camera method• Doctors’ offices pour plaster into the foam, let dry, and cure
with UV light. Buy/build an image-capturing machine for SoleSupports to digitize impressions.
• Advantages: Foam blocks won’t crumble during shipping,storage space freed up, removes step in manufacturingprocess.
• Disadvantages: Doctors may still need to recast patients’ feetif improperly done, excess shipping time still there.
2. Scanner method• Doctors’ offices have scanner apparatus and email the
scanned image to Sole Supports.• Advantages: Foam blocks won’t crumble during shipping,
Sole Supports can check for improper casting almostimmediately, frees up storage space over time.
• Disadvantages: Upfront cost.We chose the scanner method because it solved all the problemsSole Supports needed to fix and had the fewest disadvantages:
scan
ner scanned
foot impression
Python Computerprogram
Scaled.txt file
Sole Supports 3D MillingMachine
PROOF OF CONCEPTPROOF OF CONCEPT
• are flexible, not rigid.• tend to flatten out without support (which can become permanent over time).• affect the position and stress placed on the ankles, knees, hips, and back. Many alignment problems can be traced to improper arch support.
Specific arch structures are unique to each person,but there are several common characteristicsamong people. Arches:
Because the arch has such an important role in proper alignment, andbecause each person has different arch structure, not only does the archneed support, but the support given also needs to be custom-made forthat arch. This is the idea upon which Sole Supports is based.
We used MS Excel to take a sampling of measurements from which weobtained a linear equation. This equation was used to scale the scannedimage to real-world dimensions. These dimensions were then plotted onthe x, y, and z axes in a program called RHINO, as shown in the picturebelow. Sole Supports will use RHINO to export the points to the 3Dmilling machine. This machine will mill out an identical copy of theoriginal foam block that was scanned in by the doctors’ offices. SoleSupports may continue the manufacturing process, having eliminatedexcess shippingtime and costs.When theinsole iscomplete, SoleSupports will beable to keep anelectronic copyof the datarather thanbulky plastercasts, solvingboth problemspresented bySole Supports.