# US 9,738,036 B2 · Method of manufacture of a surgical model for an anatomical feature > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,738,036 B2 - Document ID: US9738036B2 - Status: Granted - Kind: B2 - Application number: 14/556,399 - Filed: 2014-12-01 - Published: 2016-06-02 - Granted: 2017-08-22 - Earliest claimed: 2014-12-01 - Assignees: Cranial Technologies, Inc. - Applicants: Cranial Technologies, Inc. - Inventors: Timothy R Littlefield - Web page: https://patentgrep.com/patent/US9738036B2 ## CPC - B29C 64/386: Data acquisition or data processing for additive manufacturing - B29C 64/393: for controlling or regulating additive manufacturing processes - G05B 19/40937: {concerning programming of machining or material parameters, pocket machining} - G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing - G06T 7/579: from motion - G06T 7/596: {from three or more stereo images} - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 80/00: Products made by additive manufacturing - G05B 2219/35134: 3-D cad-cam - G05B 2219/35143: Reconstruct free form surfaces - G05B 2219/49007: Making, forming 3-D object, model, surface - G06T 2207/30052: Implant; Prosthesis - H04N 13/239: using two two-dimensional [2D] image sensors having a relative position equal to or related to the interocular distance (H04N13/243 takes precedence) - H04N 13/282: for generating image signals corresponding to three or more geometrical viewpoints, e.g. multi-view systems - Y02P 90/02: Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS] - 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) - 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) - G06T: IMAGE DATA PROCESSING OR GENERATION, IN GENERAL - 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 - H04N: PICTORIAL COMMUNICATION, e.g. TELEVISION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method for manufacturing a model of an anatomical feature comprises utilizing a stereographic digital image camera at a plurality of different vantage points relative to a reference anatomical feature to capture a plurality of three dimensional digital image pairs of a corresponding plurality of external surface portions of the reference anatomical feature including concavities and convexities of complex anatomical surfaces, and processing the plurality of three dimensional digital image pairs to produce a three dimensional digital surface image of the reference anatomical feature and a corresponding data file. A modified three dimensional digital surface image and corresponding modified data file may be produced by utilizing one or more of selecting a portions of said three dimensional digital surface image, scaling the three dimensional digital surfaced image, and generating a mirror image of the three dimensional digital surface image. ## Claims ### Claim 1 A method for manufacturing a model of an anatomical feature of a subject, comprising: utilizing a stereographic digital image camera at a plurality of different vantage points relative to a reference anatomical feature to capture a plurality of three dimensional digital image pairs of a corresponding plurality of external surface portions of said reference anatomical feature; and processing said plurality of three dimensional digital image pairs to produce a three dimensional digital surface image of said reference anatomical feature and a corresponding data file, said processing comprises: processing said plurality of said stereographic digital image pairs to produce three dimensional digital image surface portions each corresponding to one of said plurality of external surface portions of said reference anatomical feature; and identifying one or more identified non-deformable and deformable surface portions of said subject captured in said three dimensional image surface portions for registration of said three dimensional image portions. ### Claim 2 (depends on 1) A method in accordance with claim 1, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 3 (depends on 2) A method in accordance with claim 2, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 4 (depends on 2) A method in accordance with claim 2, wherein: said model is a surgical model. ### Claim 5 (depends on 2) A method in accordance with claim 2, comprising: manufacturing said model from an autoclavable material. ### Claim 6 (depends on 2) A method in accordance with claim 2, wherein: said anatomical feature is an ear. ### Claim 7 (depends on 1) A method in accordance with claim 1, comprising: modifying said data file to provide a modified data file. ### Claim 8 (depends on 7) A method in accordance with claim 7, comprising: modifying said data file by one or more of selecting a portion of said three dimensional digital surface image, scaling said three dimensional digital surface image, and forming a mirror image of said three dimensional digital surface image. ### Claim 9 (depends on 7) A method in accordance with claim 7, comprising: utilizing said modified data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 10 (depends on 9) A method in accordance with claim 9, comprising: providing said modified data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 11 (depends on 7) A method in accordance with claim 7, wherein: said model is a surgical model. ### Claim 12 (depends on 7) A method in accordance with claim 7, comprising: manufacturing said model from an autoclavable material. ### Claim 13 (depends on 7) A method in accordance with claim 7, wherein: said anatomical feature is an ear. ### Claim 14 (depends on 1) A method in accordance with claim 1, wherein, said processing comprises: registering each of said three dimensional digital image surface portions to provide registered three dimensional image surface portions; and fusing together said registered three dimensional digital image surface portions to generate said three dimensional digital surface image of said anatomical portion and said data file. ### Claim 15 (depends on 14) A method in accordance with claim 14, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 16 (depends on 15) A method in accordance with claim 15, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 17 (depends on 14) A method in accordance with claim 14, wherein: said model is a surgical model. ### Claim 18 (depends on 14) A method in accordance with claim 14, comprising: manufacturing said model from an autoclavable material. ### Claim 19 (depends on 14) A method in accordance with claim 14, wherein: said anatomical feature is an ear. ### Claim 20 (depends on 14) A method in accordance with claim 14, comprising: modifying said data file to provide a modified data file. ### Claim 21 (depends on 20) A method in accordance with claim 20, comprising: modifying said data file by one or more of selecting a portion of said three dimensional digital surface image, scaling said three dimensional digital surface image, and forming a mirror image of said three dimensional digital surface image. ### Claim 22 (depends on 20) A method in accordance with claim 20, comprising: utilizing said modified data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 23 (depends on 20) A method in accordance with claim 20, comprising: providing said modified data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 24 (depends on 20) A method in accordance with claim 20, wherein: said model is a surgical model. ### Claim 25 (depends on 20) A method in accordance with claim 20, comprising: manufacturing said model from an autoclavable material. ### Claim 26 (depends on 20) A method in accordance with claim 20, wherein: said anatomical feature is an ear. ### Claim 27 (depends on 14) A method in accordance with claim 14, wherein: said registering step comprises utilizing one or more identified non-deformable and deformable surface portions captured in said three dimensional image surface portions. ### Claim 28 (depends on 27) A method in accordance with claim 27, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 29 (depends on 28) A method in accordance with claim 28, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 30 (depends on 27) A method in accordance with claim 27, wherein: said model is a surgical model. ### Claim 31 (depends on 27) A method in accordance with claim 27, comprising: manufacturing said model from an autoclavable material. ### Claim 32 (depends on 14) A method in accordance with claim 14, wherein: said anatomical feature is an ear. ### Claim 33 (depends on 27) A method in accordance with claim 27, comprising: modifying said data file to provide a modified data file. ### Claim 34 (depends on 33) A method in accordance with claim 33, comprising: modifying said data file by one or more of selecting a portion of said three dimensional digital surface image, scaling said three dimensional digital surface image, and forming a mirror image of said three dimensional digital surface image. ### Claim 35 (depends on 34) A method in accordance with claim 34, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 36 (depends on 34) A method in accordance with claim 34, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 37 (depends on 34) A method in accordance with claim 34, wherein: said model is a surgical model. ### Claim 38 (depends on 34) A method in accordance with claim 34, comprising: manufacturing said model from an autoclavable material. ### Claim 39 (depends on 34) A method in accordance with claim 34, wherein: said anatomical feature is an ear. ### Claim 40 (depends on 27) A method in accordance with claim 27, comprising: cropping each of said plurality of three dimensional image surface portions. ### Claim 41 (depends on 40) A method in accordance with claim 40, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 42 (depends on 41) A method in accordance with claim 41, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 43 (depends on 40) A method in accordance with claim 40, wherein: said model is a surgical model. ### Claim 44 (depends on 40) A method in accordance with claim 40, comprising: manufacturing said model from an autoclavable material. ### Claim 45 (depends on 40) A method in accordance with claim 40, wherein: said anatomical feature is an ear. ### Claim 46 (depends on 14) A method in accordance with claim 14, comprising: cropping each of said plurality of three dimensional image surface portions. ### Claim 47 (depends on 46) A method in accordance with claim 46, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 48 (depends on 44) A method in accordance with claim 44, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 49 (depends on 47) A method in accordance with claim 47, wherein: said model is a surgical model. ### Claim 50 (depends on 47) A method in accordance with claim 47, comprising: manufacturing said model from an autoclavable material. ### Claim 51 (depends on 47) A method in accordance with claim 47, wherein: said anatomical feature is an ear. ### Claim 52 (depends on 46) A method in accordance with claim 46, wherein: said registering step comprises utilizing an anatomical shape of said ear and said one or more non-deformable and deformable surface portions captured in said three dimensional image. ### Claim 53 (depends on 52) A method in accordance with claim 52, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 54 (depends on 53) A method in accordance with claim 53, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 55 (depends on 53) A method in accordance with claim 53, wherein: said model is a surgical model. ### Claim 56 (depends on 53) A method in accordance with claim 53, comprising: manufacturing said model from an autoclavable material. ### Claim 57 (depends on 53) A method in accordance with claim 53, wherein: said anatomical feature is an ear. ### Claim 58 (depends on 14) A method in accordance with claim 14, wherein: said registering step comprises utilizing an anatomical shape of said ear and said one or more non-deformable and deformable surface portions captured in said three dimensional surface image portions for registration of said three dimensional surface image portions. ### Claim 59 (depends on 58) A method in accordance with claim 58, comprising: utilizing said data file to manufacture said model, said model being one or both of a positive and negative model. ### Claim 60 (depends on 59) A method in accordance with claim 59, comprising: providing said data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model. ### Claim 61 (depends on 59) A method in accordance with claim 59, wherein: said model is a surgical model. ### Claim 62 (depends on 59) A method in accordance with claim 59, comprising: manufacturing said model from an autoclavable material. ### Claim 63 (depends on 59) A method in accordance with claim 59, wherein: said anatomical feature is an ear. ### Claim 64 A surgical model of an ear manufactured by a process comprising the steps of: utilizing a stereographic digital image camera at a plurality of different vantage points relative to a reference ear to capture a plurality of three dimensional digital image pairs of a corresponding plurality of external surface portions of said reference ear including concavities and convexities of said ear and at least a portion of the external ear canal of said reference ear; processing said plurality of three dimensional digital image pairs to produce a three dimensional digital surface image of said reference ear comprising said concavities and convexities of said reference ear and said at least a portion of the external ear canal of said reference ear and a corresponding data file; said processing said plurality of said stereographic digital image pairs comprises: producing three dimensional digital image surface portions each corresponding to one of said plurality of external surface portions of said reference ear; identifying one or more non-deformable and deformable surface portions of said subject captured in said three dimensional image surface portions for registration of said three dimensional digital image surface portions; utilizing said one or more non-deformable and deformable surface portions for registration of said three dimensional image portions; and utilizing said data file to manufacture said surgical model, said model being one or both of a positive and negative model. ### Claim 65 (depends on 64) A surgical model of an ear manufactured in accordance with the process of claim 64, comprising the further step of: modifying said data file to provide a modified data file by one or more of selecting a portion of said three dimensional digital surface image, scaling said three dimensional digital surface image and forming a mirror image of said three dimensional digital surface image. ### Claim 66 (depends on 65) A surgical model of an ear manufactured in accordance with the process of claim 65, comprising the further steps of: providing said modified data file to a three dimensional printer; and utilizing said three dimensional printer to manufacture said model from a plastic material. ### Claim 67 (depends on 66) A surgical model of an ear manufactured in accordance with the process of claim 66, wherein: said plastic material is autoclavable. ### Claim 68 (depends on 67) A surgical model of an ear manufactured in accordance with the process of claim 67, further comprising the steps of: registering each of said three dimensional digital image surface portions to provide registered three dimensional image surface portions; and fusing together said registered three dimensional digital image surface portions to generate said three dimensional digital surface image of said anatomical portion and said data file. ### Claim 69 (depends on 64) A surgical model of an ear manufactured in accordance with the process of claim 64, wherein: said surgical model comprises a plastic material. ### Claim 70 (depends on 69) A surgical model of an ear manufactured in accordance with the process of claim 69, wherein: said plastic material is autoclavable. ### Claim 71 (depends on 64) A surgical model of an ear manufactured in accordance with the process of claim 64, further comprising the steps of: registering each of said three dimensional digital image surface portions to provide registered three dimensional image surface portions; and fusing together said registered three dimensional digital image surface portions to generate said three dimensional digital surface image of said reference ear and said data file. ### Claim 72 (depends on 71) A surgical model of an ear manufactured in accordance with the process of claim 71, wherein: said registering step comprises utilizing said one or more non-deformable and deformable surface portions captured in said three dimensional image surface portions for registration of said three dimensional image portions. ### Claim 73 (depends on 72) A surgical model of an ear manufactured in accordance with the process of claim 72, wherein: said surgical model comprises a plastic material. ### Claim 74 (depends on 73) A surgical model of an ear manufactured in accordance with the process of claim 73, wherein: said plastic material is autoclavable.