Methods for making prosthetic surfaces

Abstract

Methods for reproducing a 3D object surface are provided. A preferred method according to this invention includes (1) identifying a real object surface, (2) acquiring at least a 3D data set with a 3D surface imaging device, (3) acquiring at least a 2D data set using a 2D surface imaging device with a surface resolution of at least about 0.1 mm 2 , (4) synthesizing a 3D composite data set by orienting a first virtual image of the first data set and a second virtual image of the second data set to form a composite virtual image that corresponds to the composite data set, and (5) making a reproduction of the object surface with the composite data set. Orientation of the virtual images is relative to each other and without substantial loss of surface resolution.

I claim:  
     
         1 . A method for reproducing a 3D object surface comprising: 
 identifying a real object surface having at least one measurable dimension;    acquiring at least a 3D data set using a 3D imaging device, said 3D data set depicting said object surface;    acquiring at least a 2D second data set using a second surface imaging device, the second data set depicting said object surface and having a surface resolution of at least about 0.1 mm 2 ;    synthesizing a 3D composite data set by orienting, relative to each other and without substantial loss of said surface resolution, a first virtual image of said first data set and a second virtual image of said second data set to form a composite virtual image, said composite virtual image corresponding to said composite data set; and    making a reproduction of said object surface with said composite data set.    
     
     
         2 . The method of    claim 1    wherein said acquiring said 3D data set comprises: 
 building a negative mold of said object surface;  
 building a positive mold of said real object surface using said negative mold; and  
 accumulating said 3D data set depicting said positive model surface.  
 
     
     
         3 . The method of    claim 2    further comprising depositing a highly reflective coat on said positive mold before said accumulating.  
     
     
         4 . The method of    claim 2    wherein said building said negative mold comprises impressing said object in a moldable material selected from a group consisting of an RTV molding material and an alginate.  
     
     
         5 . The method of    claim 1    wherein said acquiring said 3D data set comprises scanning said object surface with said 3D imaging device selected from a group consisting of a laser measuring device, a stereoscopic measuring device, a polarization measuring device, and an ultrasonic measuring device.  
     
     
         6 . The method of    claim 5    wherein said acquiring said 2D data set comprises accumulating said 2D data set by photographing said object with a digital camera, said 2D data set having at least gray scale information.  
     
     
         7 . The method of    claim 5    wherein said acquiring said 2D data set comprises: 
 photographing said object with an analog camera to create an analog photograph; and  
 digitizing said analog photograph to create said 2D data set depicting said photograph, said 2D data set having at least gray scale information.  
 
     
     
         8 . The method of    claim 5    wherein said acquiring said 2D data set comprises: 
 making a drawing by an artist; and  
 digitizing said drawing to obtain said 2D data set depicting said drawing, said 2D data set having at least gray scale information.  
 
     
     
         9 . The method of    claim 5    wherein said acquiring said 2D data set comprises: 
 tracing said real object to obtain a projected outline; and  
 digitizing said outline to obtain said 2D data set depicting said outline.  
 
     
     
         10 . The method of    claim 5    wherein said acquiring said 2D data set comprises: 
 photographing said object to obtain a projected outline; and  
 digitizing said outline to obtain said 2D data set depicting said outline.  
 
     
     
         11 . The method of    claim 5    further comprising measuring said object with a tape measure to obtain said at least one measurable dimension.  
     
     
         12 . The method of    claim 5    wherein said synthesizing comprises reversing at least one of said data sets so that said making said reproduction comprises making a reverse reproduction.  
     
     
         13 . The method of    claim 12    wherein said reversing comprises reversing said composite data set.  
     
     
         14 . The method of    claim 5    further comprising synthesizing a composite data subset that depicts a portion of said surface of said virtual image.  
     
     
         15 . The method of    claim 14    wherein said synthesizing said subset comprises: 
 selecting said portion of said surface of said virtual image; and  
 creating said composite data subset, said subset being separately manipulatable from said composite data set.  
 
     
     
         16 . The method of    claim 5    wherein said synthesizing said composite data set comprises calibrating said composite data set with said at least one measurable dimension.  
     
     
         17 . The method of    claim 5    further comprising modifying a target data set to include at least one cosmetic detail, said target data set being selected from a group consisting of said composite data set and said composite data subset.  
     
     
         18 . The method of    claim 17    wherein said modifying comprises modifying said target data set with a cosmetic detail selected from a group consisting of a kinetic detail, an authentic detail, and a desired detail.  
     
     
         19 . The method of    claim 5    wherein said synthesizing comprises increasing a contrast level of a target data set by deleting a middle portion of a gray scale associated with said target data set, said target data set being selected from a group consisting of said at least said 3D data set, said at least said 2D data set, and said composite data set.  
     
     
         20 . The method of    claim 5    wherein said synthesizing comprises establishing a substantially uniform contrast level in said composite data set.  
     
     
         21 . The method of    claim 5    wherein said synthesizing comprises adding mold information to said composite data set for fabricating a mold for making said reproduction, said mold information including mold structure information and mold thickness information.  
     
     
         22 . The method of    claim 21    wherein said adding mold information comprises orienting a matrix of virtual structural elements relative to said virtual composite image.  
     
     
         23 . The method of    claim 22    wherein said synthesizing comprises amending said composite data set so that a portion of said virtual image surface is adapted to accurately conform to a different virtual. surface.  
     
     
         24 . The method of    claim 23    wherein said real object surface includes at least a first real surface and a second real surface, said first real surface being a surface of a human limb and said second real surface being a surface of a counterpart stump.  
     
     
         25 . A method for making a prosthetic skin for covering a prosthetic device that replaces a missing limb that attaches to a stump, said method comprising: 
 acquiring at least a first data set with a surface imaging device, said first data set depicting a surface of an original limb and having a surface resolution of at least about 0.1 mm 2 ;    synthesizing a 3D composite data set from said first data set, said composite data set depicting said prosthetic skin without substantial loss of said surface resolution;    providing said composite data set to a digitally controlled fabrication device, wherein said fabrication device is selected from a group comprising a fused deposition modeling device, stereo lithographic device, 3D electroforming system, a laminated object manufacturing system, a solid ground curing device, and a 3D printing device;    fabricating a negative mold with said fabrication device using said composite data set, said mold substantially depicting said prosthetic skin; and    fabricating said prosthetic skin with. said mold.    
     
     
         26 . The method of    claim 25    wherein said original limb is said missing limb.  
     
     
         27 . The method of    claim 25    wherein said original limb is a counterpart of said missing limb, said method further comprising reversing one of said data sets so that said prosthetic skin substantially corresponds to said missing limb.  
     
     
         28 . The method of    claim 25    wherein said fabricating said mold comprises fabricating a negative mold with a high resolution epoxy.  
     
     
         29 . The method of    claim 25    wherein said fabricating said mold comprises: 
 fabricating a positive mold with a polymer-wax; and  
 fabricating a negative mold from said positive mold using a material selected from a group consisting of an epoxy, a phenolic resin, silicone, and an electroformed metal.  
 
     
     
         30 . The method of    claim 25    wherein said fabricating said negative mold comprises: 
 building a lining that has the negative shape of said prosthetic skin;  
 building a matrix of hollow structural elements according to said composite data set; and  
 investing said matrix with a matrix investing material.  
 
     
     
         31 . The method of    claim 30    wherein said lining has a thickness between about 2 mm and about 10 mm.  
     
     
         32 . The method of    claim 30    wherein said matrix has a thickness of between about 1 mm and about 10 mm.  
     
     
         33 . The method of    claim 30    wherein said investing comprises investing said matrix with a metal-epoxy resin.  
     
     
         34 . The method of    claim 30    wherein said fabricating said skin comprises coating said lining with at least one coat of silicone material, said at least one coat having a first surface that substantially contacts said lining and a second surface that does not substantially contact said lining.  
     
     
         35 . The method of    claim 34    wherein said coating comprises: 
 coating said lining with at least a first coat of silicone material that contacts said lining; and  
 coating said first coat with at least a second coat of silicone material that substantially does not contact said lining, said second coat having a silica concentration greater than said first coat.  
 
     
     
         36 . The method of    claim 34    wherein said coating comprises: 
 depositing said coat on said lining;  
 degassing said silicone material;  
 drying said coat while rotating said mold to ensure that said prosthetic skin has a substantially uniform thickness; and  
 curing said coat by heating it above room temperature.  
 
     
     
         37 . The method of    claim 34    further comprising roughening said second surface of said coat.  
     
     
         38 . The method of    claim 34    further comprising: 
 removing said prosthetic skin from said mold; and  
 finishing said skin by adding color to an inner surface of said at least one coat.  
 
     
     
         39 . The method of    claim 38    further comprising: 
 inserting an armature inside said prosthetic skin; and  
 filling said prosthetic skin with a fill material selected from a group consisting of silicone or urethane foam.  
 
     
     
         40 . The method of    claim 25    further comprising depositing medical grade material on a portion of said prosthetic skin that contacts said stump.  
     
     
         41 . A reproduction of a real object surface having a surface resolution of at least about 0.1 mm2, said reproduction being made according to a method comprising: 
 identifying a real object surface having at least one measurable dimension;    acquiring at least a 3D data set using a 3D imaging device, said 3D data set depicting said object surface;    acquiring at least a 2D second data set using a second surface imaging device, the second data set depicting said object surface and having a surface resolution of at least about 0.1 mm2;    synthesizing a 3D composite data set by orienting, relative to each other and without substantial loss of said surface resolution, a first virtual image of said first data set and a second virtual image of said second data set to form a composite virtual image, said composite virtual image corresponding to said composite data set; and    making the reproduction of said object surface with said composite data set.    
     
     
         42 . The reproduction of    claim 41    wherein said acquiring said 3D data set comprises: 
 building a negative mold of said object surface;  
 building a positive mold of said real object surface using said negative mold; and  
 accumulating said 3D data set depicting said positive model surface.  
 
     
     
         43 . The reproduction of    claim 41    wherein said acquiring said 2D data set comprises: 
 accumulating by photographing said object with a digital camera, said 2D data set having at least gray scale information.  
 
     
     
         44 . The reproduction of    claim 41    wherein said acquiring said 2D data set comprises: 
 photographing said object with an analog camera to create an analog photograph; and  
 digitizing said analog photograph to create said 2D data set depicting said photograph, said 2D data set having at least gray scale information.  
 
     
     
         45 . The reproduction of    claim 41    wherein said acquiring said 2D data set comprises: 
 making a drawing; and  
 digitizing said drawing to obtain said 2D data set depicting said drawing, said 2D data set having at least gray scale information.  
 
     
     
         46 . The reproduction of    claim 41    wherein said acquiring said 2D data set comprises: 
 tracing said real object to obtain a projected outline; and  
 digitizing said outline to obtain said 2D data set depicting said outline.  
 
     
     
         47 . The reproduction of    claim 41    wherein said acquiring said 2D data set comprises: 
 photographing said object to obtain a projected outline; and  
 digitizing said outline to obtain said 2D data set depicting said outline.  
 
     
     
         48 . The reproduction of    claim 41    wherein said synthesizing comprises: 
 reversing at least one of said data sets so that said reproduction is a reverse reproduction.  
 
     
     
         49 . The reproduction of    claim 48    wherein said reversing comprises reversing said composite data set.  
     
     
         50 . The reproduction of    claim 48    wherein said real object surface includes at least a first real surface and a second real surface, said first real surface being a surface of a human limb and said second real surface being a surface of a counterpart stump.  
     
     
         51 . The reproduction of    claim 41    wherein said reproduction has at least one cosmetic detail, and wherein said method further comprises: 
 modifying a target data set to include said at least one cosmetic detail, said target data set being selected from a group consisting of said composite data set and a composite data subset.  
 
     
     
         52 . A prosthetic skin reproduction having a surface resolution of at least about 0.1 mm2 for covering a prosthetic device that replaces a missing limb and that attaches to a stump, said skin being made according to a method comprising: 
 acquiring at least a first data set with a surface imaging device, said first data set depicting a surface of an original limb and having a surface resolution of at least about 0.1 mm2;    synthesizing a 3D composite data set from said first data set, said composite data set depicting said prosthetic skin without substantial loss of said surface resolution;    providing said composite data set to a digitally controlled fabrication device, wherein said fabrication device is selected from a group comprising a fused deposition modeling device, stereo lithographic device, 3D electroforming system, a laminated object manufacturing system, a solid ground curing device, and a 3D printing device;    fabricating a negative mold with said fabrication device using said composite data set, said mold substantially depicting said prosthetic skin; and    fabricating said prosthetic skin with said mold.    
     
     
         53 . The skin of    claim 52    wherein said original limb is said missing limb.  
     
     
         54 . The skin of    claim 52    wherein said original limb is a counterpart of said missing limb, said method further comprising reversing one of said data sets so that said prosthetic skin substantially corresponds to said missing limb.  
     
     
         55 . The skin of    claim 52    wherein said fabricating said mold comprises fabricating a negative mold with a high resolution epoxy.  
     
     
         56 . The skin of    claim 52    wherein said fabricating said mold comprises: 
 fabricating a positive mold with a polymer-wax; and  
 fabricating a negative mold from said positive mold using a material selected from a group consisting of an epoxy, a phenolic resin, silicone, and an electroformed metal.  
 
     
     
         57 . The skin of    claim 52    wherein said fabricating said negative mold comprises: 
 building a lining that has the negative shape of said prosthetic skin;  
 building a matrix of hollow structural elements according to said composite data set; and  
 investing said matrix with a matrix investing material.  
 
     
     
         58 . The skin of    claim 57    wherein said building a lining comprises building a lining having a thickness between about 2 mm and about 10 mm.  
     
     
         59 . The skin of    claim 57    wherein said building a matrix comprises building a matrix having a thickness of between about 1 mm and about 10 mm.  
     
     
         60 . The skin of    claim 57    wherein said investing comprises investing said matrix with a metal-epoxy resin.  
     
     
         61 . The skin of    claim 57    wherein said fabricating said skin comprises coating said lining with at least one coat of silicone material, said at least one coat having a first surface that substantially contacts said lining and a second surface that does not substantially contact said lining.  
     
     
         62 . The skin of    claim 61    wherein said coating comprises: 
 coating said lining with at least a first coat of silicone material that contacts said lining; and  
 coating said first coat with at least a second coat of silicone material that substantially does not contact said lining, said second coat having a silica concentration greater than said first coat.  
 
     
     
         63 . The skin of    claim 61    wherein said coating comprises: 
 depositing said coat on said lining;  
 degassing said silicone material;  
 drying said coat while rotating said mold to ensure that said prosthetic skin has a substantially uniform thickness; and  
 curing said coat by heating it above room temperature.  
 
     
     
         64 . The skin of    claim 61    wherein said method further comprises roughening said second surface of said coat.  
     
     
         65 . The skin of    claim 61    wherein said method further comprises: 
 removing said prosthetic skin from said mold; and  
 finishing said skin by adding color to an inner surface of said at least one coat.  
 
     
     
         66 . The skin of    claim 65    wherein said method further comprises: 
 inserting an armature inside said prosthetic skin; and  
 filling said prosthetic skin with a fill material selected from a group consisting of silicone or urethane foam.  
 
     
     
         67 . The skin of    claim 52    wherein said method further comprises depositing medical grade material on a portion of said prosthetic skin that contacts said stump.  
     
     
         68 . A prosthetic limb for a patient, said patient having a first limb and a counterpart stump that corresponds to a missing limb, said prosthetic limb being for replacement of said missing limb and attachment to said stump, said prosthetic limb comprising: 
 a prosthetic device;    a prosthetic skin for covering said prosthetic device, said prosthetic skin being substantially a mirror image of said first limb.    
     
     
         69 . The limb of    claim 68    wherein said skin has a surface resolution of at least about 0.1 mm2.  
     
     
         70 . The limb of    claim 68    wherein said skin has a cosmetic detail that is different from said first limb.  
     
     
         71 . The limb of    claim 68    wherein said prosthetic limb is selected from a group comprising an arm, any part of an arm, a leg, and any part of a leg.  
     
     
         72 . The limb of    claim 68    wherein said prosthetic limb is without seams.