Custom cranial remodeling devices manufactured by additive manufacture
A custom cranial remodeling device to correct a deformed head of a subject comprises an inner layer shaped to contact the head of the subject at predetermined areas, the inner layer is deposited by an additive manufacturing device and an outer layer deposited by the additive manufacturing device. The inner layer and the outer layer are each formed by the additive manufacture device utilizing a device data file derived from a subject data file, the subject data file representative of the shape of the deformed head, the device data file determining the shape of the cranial remodeling device to correct the shape of the deformed head.
1 . A subject specific cranial remodeling device custom manufactured to modify a deformed head shape of a current subject, comprising: an interior surface shaped to modify said deformed head shape of said current subject as head grows, said interior surface comprising additive manufacture deposited material; an outer surface comprising additive manufacture deposited material; said interior surface and said outer surface specific to said deformed head shape of said current subject and each having a shape and contour lines provided by a device data file representative of a current subject specific shape of said subject specific cranial remodeling device; and said device data file comprising at least said outer surface having said contour lines calculated from one or more mathematically defined predetermined anthropometric locations and calculated curvatures on said deformed head shape of said current subject.
2 . The subject specific cranial remodeling device of claim 1 , comprising: a plurality of additive manufacture deposited layers disposed between said interior surface and said outer surface.
3 . The subject specific cranial remodeling device of claim 2 , wherein: at least one of said plurality of additive manufacture deposited layers comprises a cellular configuration.
4 . The subject specific cranial remodeling device of claim 2 , wherein: at least one of said plurality of additive manufacture deposited layers comprises carbon fibers integrated therein.
5 . The subject specific cranial remodeling device of claim 1 , comprising: at least one intermediate layer between said interior surface and said outer surface said intermediate layer comprising additive manufacture deposited material.
6 . The subject specific cranial remodeling device of claim 1 , comprising: said interior surface carried on an inner layer, said outer surface carried on an outer layer.
7 . The subject specific cranial remodeling device of claim 1 , comprising: said device data file is derived from a current subject data file representing said deformed head shape of said current subject and a modified data file representative of a modified head shape for said current subject.
8 . The subject specific cranial remodeling device of claim 1 , wherein: said interior surface comprises portions configured to limit growth of said head at predetermined surface areas of said head.
9 . The subject specific cranial remodeling device of claim 1 , comprising: one or more electronic transducers manufactured into said subject specific cranial remodeling device.
10 . The subject specific cranial remodeling device of claim 1 , comprising: one or more electronic transducers useable to determine one or more of tilt and turn of said head, whether said subject specific cranial remodeling device is being worn, and the frequency of predetermined head motions.
11 . The subject specific cranial remodeling device of claim 1 , comprising: components integrally formed with said subject specific cranial remodeling device.
12 . The subject specific cranial remodeling device of claim 1 , comprising: one or more of apparatus for fastening said subject specific cranial remodeling device in place on said head, electronic transducers, and electronic sensors.
13 . The subject specific cranial remodeling device of claim 1 , comprising: said interior surface comprises one or more separate portions configured to limit growth of one or more corresponding areas on said head.
14 . The subject specific cranial remodeling device of claim 1 , comprising: one or more additive manufactured electronic sensors.
15 . The subject specific cranial remodeling device of claim 1 , comprising: one or more electronic sensors operable to determine pressure levels applied to said head when said subject specific cranial remodeling device is worn on said head.
16 . The subject specific cranial remodeling device of claim 1 , comprising: one or more electronic sensors operable to confirm that said subject specific cranial remodeling device is being correctly worn on said head.