# US 9,449,141 B2 · Systems and methods for generating orthotic device models from user-based data capture

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- Number: US 9,449,141 B2
- Document ID: US9449141B2
- Status: Granted
- Kind: B2
- Application number: 14/677,894
- Filed: 2015-04-02
- Published: 2015-07-30
- Granted: 2016-09-20
- Earliest claimed: 2013-07-26
- Assignees: Sols Systems Inc.
- Applicants: Sols Systems Inc.
- Inventors: Kegan Leann Schouwenburg; Nathan Ghabour; Alexander Crosby
- Web page: https://patentgrep.com/patent/US9449141B2

## CPC

- G06F 30/17: Mechanical parametric or variational design
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- G05B 15/02: electric
- G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing
- G06F 30/00: Computer-aided design [CAD]
- G06F 30/12: characterised by design entry means specially adapted for CAD, e.g. graphical user interfaces [GUI] specially adapted for CAD
- G16B 5/00: ICT specially adapted for modelling or simulations in systems biology, e.g. gene-regulatory networks, protein interaction networks or metabolic networks
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- G05B 2219/23005: Expert design system, uses modeling, simulation, to control design process
- G05B 2219/23011: Sequence control design using pc, cad of control system CADCS
- G16H 50/50: for simulation or modelling of medical disorders
- Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- G16B: BIOINFORMATICS, i.e. INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR GENETIC OR PROTEIN-RELATED DATA PROCESSING IN COMPUTATIONAL MOLECULAR BIOLOGY
- G16H: HEALTHCARE INFORMATICS, i.e. INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR THE HANDLING OR PROCESSING OF MEDICAL OR HEALTHCARE DATA
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for generating an orthotic device is disclosed. The method includes receiving data from a client device of a patient, the data comprising patient information and image data representative of a body part of the patient. The method further includes generating, based on the image data, three-dimensional model data representative of the body part, and generating parametric CAD model data of the orthotic device based on the three-dimensional model data and the patient information. The parametric CAD model data is transmitted to a three-dimensional printer, wherein the three-dimensional printer is to generate the orthotic device based on the parametric CAD model data.

## Claims

### Claim 1

A method for producing an orthotic device customized to or custom produced for anatomy of an individual to improve biomechanics of the individual, the method comprising:
receiving, from a client device, data associated with the individual, the data comprising physical parameters of the individual and image data representative of a foot of the individual, the image data comprising a plurality of images with each image being representative of a view of the foot, wherein at least one of the plurality of images is representative of a medial view of the foot, wherein the data is acquired by the client device without requiring trained medical personnel;
computing, by a processing device, a plurality of physical dimensions of the foot of the individual by deriving the plurality of physical dimensions at least partially from the plurality of images;
generating, by the processing device, parametric computer-aided design (CAD) model data for the orthotic device based on the physical parameters of the individual, the plurality of physical dimensions of the foot, and a digital three-dimensional (3D) model of the foot to facilitate optimization of mechanical properties of the orthotic device to the individual, wherein the 3D model comprises a plurality of points representative of the individual's anatomy, wherein the 3D model is capable of being inspected, re-used, or re-processed by an algorithm executed by the processing device or updated based on new algorithms and/or updated data associated with the individual, and wherein the parametric CAD model data is descriptive of one or more surface or sub-surface structures; and
transmitting the parametric CAD model data to a fabrication device, wherein the fabrication device is to fabricate the orthotic device based on the parametric CAD model data.

### Claim 2 (depends on 1)

The method of claim 1, further comprising:
generating the 3D model of the foot based on the plurality of images and the physical parameters of the individual, wherein deriving the plurality of physical dimensions comprises further deriving the plurality of physical dimensions at least partially from the 3D model of the foot.

### Claim 3 (depends on 1)

The method of claim 1, wherein the plurality of physical dimensions of the foot are further derived at least partially from the physical parameters of the individual.

### Claim 4 (depends on 1)

The method of claim 1, wherein the physical parameters of the individual comprise a measured foot length, and wherein deriving the plurality of physical dimensions at least partially from the plurality of images comprises scaling at least one of the plurality of physical dimensions based on the measured foot length.

### Claim 5 (depends on 1)

The method of claim 1, wherein the client device is associated with the individual or a physician.

### Claim 6 (depends on 1)

The method of claim 1, wherein at least some of the image data or the physical parameters was received from an additional client device.

### Claim 7 (depends on 1)

The method of claim 1, further comprising:
receiving inertial measurement unit data from the client device, wherein deriving the plurality of physical dimensions comprises further deriving the plurality of physical dimensions based at least partially on the inertial measurement unit data.

### Claim 8

A system for producing an orthotic device customized to or custom produced for anatomy of an individual to improve biomechanics of the individual, the system comprising:
a memory; and
a processing device communicatively coupled to the memory, wherein the processing device is to:
receive, from a client device, data associated with the individual, the data comprising physical parameters of the individual and image data representative of a foot of the individual, the image data comprising a plurality of images with each image being representative of a view of the foot, wherein at least one of the plurality of images is representative of a medial view of the foot, wherein the data is acquired by the client device without requiring trained medical personnel;
compute a plurality of physical dimensions of the foot of the individual by deriving the plurality of physical dimensions at least partially from the plurality of images;
generate parametric CAD model data for the orthotic device based on the physical parameters of the individual, the plurality of physical dimensions of the foot, and a digital 3D model of the foot to facilitate optimization of mechanical properties of the orthotic device to the individual, wherein the 3D model comprises a plurality of points representative of the individual's anatomy, wherein the 3D model is capable of being inspected, re-used, or re-processed by an algorithm executed by the processing device or updated based on new algorithms and/or updated data associated with the individual, and wherein the parametric CAD model data is descriptive of one or more surface or sub-surface structures; and
transmit the parametric CAD model data to a fabrication device, wherein the fabrication device is to fabricate the orthotic device based on the parametric CAD model data.

### Claim 9 (depends on 8)

The system of claim 8, wherein the processing device is further to:
generate the 3D model of the foot based on the plurality of images and the physical parameters of the individual,
wherein, to derive the plurality of physical dimensions, the processing device is further to derive the plurality of physical dimensions at least partially from the 3D model of the foot.

### Claim 10 (depends on 8)

The system of claim 8, wherein the plurality of physical dimensions of the foot are to be derived at least partially from the physical parameters of the individual.

### Claim 11 (depends on 8)

The system of claim 8, wherein the physical parameters of the individual comprise a measured foot length, wherein, to derive the plurality of physical dimensions at least partially from the plurality of images, the processing device is further to scale at least one of the plurality of physical dimensions based on the measured foot length.

### Claim 12 (depends on 8)

The system of claim 8, wherein the client device is associated with the individual or a physician.

### Claim 13 (depends on 8)

The system of claim 8, wherein processing device is to receive at least some of the image data or the physical parameters from an additional client device.

### Claim 14 (depends on 8)

The system of claim 8, wherein the processing device is further to:
receive inertial measurement unit data from a client device,
wherein, to derive the plurality of physical dimensions, the processing device is further to derive the plurality of physical dimensions based at least partially on the inertial measurement unit data.