Method for automating custom-fitting joint brace

1. A computer-implemented method for automating a design and manufacture of a custom designed joint brace or orthotic device, the method comprising:

providing a digital depth camera capable of three-dimensional (3D) scanning;

obtaining a 3D surface scan of a human joint, limb, or body part using the depth camera;

processing compiled scan data;

converting geometric relationships based on points derived from the 3D surface scan to instructions or values;

applying digital transformations to cross-sections and/or device reference points to modify a virtual 3D pre-designed base device based on the instructions or values to create a virtual custom device; and

manufacturing the joint brace or orthotic device based on the virtual custom device.

2. The method according to claim 1 , further comprising:

separating the virtual 3D pre-designed base device into two or more component parts;

representing a shape of the two or more component parts with a pre-defined number of cross-sections;

using three or more points derived from the 3D surface scan or reference geometries to define the pre-defined number of cross-sections;

calculating geometric relationships of the points derived from the 3D surface scan or the reference geometries with the 3D surface scan;

calculating one or more translations for three or more device reference points or device reference geometries within each cross-section for fitting to the 3D surface scan;

applying the translations to the device reference points or the device reference geometries;

calculating rotations for each of the three or more device reference points or device reference geometries for fitting to the 3D surface scan;

applying the calculated rotations to all the device reference points or device reference geometries.

3. The method according to claim 2 , further comprising averagely distributing a distance between the pre-defined number of cross-sections of the virtual 3D pre-designed base device to span the entire joint brace or orthotic device.

4. The method according to claim 1 , further comprising:

digitally separating the virtual 3D pre-designed base device into two or more component parts;

aligning and fixing distances and relative orientations between the two or more component parts.

5. The method according to claim 1 , further comprising:

using three or more points derived from the 3D surface scan or reference geometries to define a pre-defined number of cross-sections of the virtual 3D pre-designed base device;

determining two or more points derived from the 3D surface scan of the three or more points derived from the 3D surface scan or reference geometries as control points and connecting them with b-spline interpolation to define a boundary of one or more of the cross-sections.

6. The method according to claim 1 , further comprising using three or more points derived from the 3D surface scan or reference geometries to define individual cross-sections of the virtual 3D pre-designed base device, and determining at least one device reference point of the device reference points or reference geometries as a center of one or more of the individual cross-sections.

7. The method according to claim 1 , further comprising:

calculating a geometric relationship of two or more points derived from the 3D surface scan;

identifying a first device reference point on the virtual 3D pre-designed base device and a closest point derived from the 3D surface scan;

applying translations to the first device reference point on the virtual 3D pre-designed base device based on its distance from the closest point derived from the 3D surface scan and the geometric relationship of the two or more points derived from the 3D surface scan.

8. The method according to claim 1 , further comprising:

determining a first point derived from the 3D surface scan;

determining a device reference point on the 3D pre-designed base device that is nearest to the first point derived from the 3D surface scan;

using the first point derived from the 3D surface scan and the device reference point, calculating a translation for the device reference point on the 3D pre-designed base device for fitting the virtual 3D pre-designed base device to the 3D surface scan; and

generating a 3D translation vector based on the calculated translation of the device reference point to create a contact point between one or more pre-defined cross sections of the virtual custom device and the 3D surface scan.

9. The method according to claim 1 , further comprising:

determining one or more device reference points on the virtual 3D pre-designed base device or virtual 3D custom device;

calculating rotations for one or more of the one or more device reference points to fit the virtual 3D pre-designed base device or virtual 3D custom device to the 3D surface scan;

calculating a rotation angle that minimizes a distance between a non-contact point of the one or more device reference points on the virtual 3D pre-designed base device or virtual 3D custom device and the 3D surface scan.

10. The method according to claim 1 , further comprising digitally writing the virtual custom device into permanent storage using a computer-aided design format.

11. The method according to claim 1 , further comprising:

adding auxiliary components to the joint brace or orthotic device, comprising one or more of strap slots, tensioning components, serial numbers, company logo, company name, or other custom designs; and

running a quality control to ensure that the body design of the joint brace or orthotic device complies with industry standards.

12. The method according to claim 1 , further comprising loading patient medical information into a database and using the patient medical information to aid in designing the joint brace or orthotic device.

13. The method according to claim 1 , further comprising loading patient medical information into a database, wherein the patient medical information includes one or more of Q angle of a user's joint, body mass index, age, weight, height, degree of patient pain, location of pain, location of pain during movement, radiographic data, or intended activity, wherein the patient medical information is incorporated automatically or semiautomatically into a mechanical design of the joint brace or orthotic device.

14. The method according to claim 1 , wherein radiographic data, Magnetic Resonance Imaging (MRI) data, Computed Tomography (CT) scan data, Position Emission Tomography (PET) scan data, X-ray data, fluoroscopy data, or ultrasound data, is input into a database and incorporated automatically or semiautomatically into a mechanical design of the joint brace or orthotic device.

15. The method according to claim 1 , further comprising automatically performing a quality control analysis on the 3D surface scan, the joint brace or orthotic device, or the virtual custom device.

16. The method according to claim 1 , wherein mechanical impedance or tissue elasticity of a body part are calculated based on patient medical information, and wherein the mechanical impedance or tissue elasticity of the body part are used to improve the fit and function of the joint brace or orthotic device.

17. The method according to claim 1 , wherein machine learning algorithms are applied to continually improve the quality of outputs, optimize a speed of designing or manufacturing, reduce required computing power, optimize transformations to achieve a more direct end result, or combinations thereof.

18. The method according to claim 1 , further comprising:

identifying locations of high stress concentrations in the virtual custom device;

applying fillets to the identified locations to improve the strength and/or durability of the virtual custom device.

19. The method according to claim 1 , wherein a type and number of component subsystems of the joint brace or orthotic device are added to the custom virtual device depending on the 3D pre-designed base device that is selected.

20. The method according to claim 1 , further comprising:

performing automated mechanical analysis of the virtual custom device; and

increasing or decreasing the infill geometry or infill density of the virtual custom device at cross sections to improve the virtual custom device's anticipated strength to weight ratio, or to improve the strength and/or durability of the joint brace or orthotic device.

21. A system for designing a custom-fitting joint brace or orthotic device comprising the following:

at least one processor;

at least one memory device coupled to the processor capable of storing computer-readable instructions which, when executed by the at least one processor, cause the system to perform the following:

using a depth camera to obtain a three-dimensional (3D) surface scan of a human limb joint, or body part using 3D scanning;

processing compiled scan data;

converting geometric relationships based on points derived from the 3D surface scan to instructions or values;

applying digital transformations to cross-sections and/or device reference points to modify a virtual 3D pre-designed base device based on the instructions or values to create a virtual custom device; and

manufacturing the joint brace or orthotic device based on the virtual custom device.

22. The system according to claim 21 , further comprising:

uploading the compiled scan data to a database;

processing and converting the compiled scan data into a format that is capable of being represented as a 3D digital object in a computer aided design system component;

defining geometric constraints based on the compiled scan data and/or 3D digital object;

digitally fitting a virtual 3D pre-designed base device to the 3D digital object;

adapting the virtual 3D pre-designed base device to a virtual custom device based on the obtained 3D surface scan and the defined geometric constraints;

performing quality control analysis on the virtual custom device;

sending a virtual custom device file to a database for fabrication.

23. A non-transitory computer-readable medium having stored instructions that, when executed by one or more processors, cause a computing device to perform functions comprising:

obtaining a 3-dimensional (3D) surface scan of a human joint, limb, or body part using 3D scanning with a depth camera;

processing compiled scan data;

converting geometric relationships based on points derived from the 3D surface scan to instructions or values; and

applying digital transformations to cross-sections and/or device reference points to modify a virtual 3D pre-designed base device based on the instructions or values to create a virtual custom device.