Systems and methods for designing and manufacturing custom immobilization molds for use in medical procedures

1. A system for processing immobilization molds for application of treatment, comprising:

a mold model generator executable on a computing system having one or more processor and memory, configured to generate a three-dimensional mold model of an immobilization mold within with a subject is to be positioned for application of a treatment, the three-dimensional dimensional mold model generated by:

subtracting, from a first composite space of the three-dimensional mold model, a second composite space corresponding to a three-dimensional scan of at least a portion of the subject to define an opening within the three-dimensional mold model;

removing, from the three-dimensional mold model, to define an imprint in the opening, a first portion along a first axis in which the subject is to enter the immobilization mold;

identifying, from a second portion of the three-dimensional mold model remaining after the removal of the first portion, one or more inward protrusions into the imprint of the three-dimensional mold model relative to a second axis intersecting the first axis; and

removing, from the three-dimensional mold model, the identified one or more inward protrusions relative to the second axis.

2. The system of claim 1 , further comprising an accessory positioner executable on the computing system, configured to:

identify, within the three-dimensional mold model, a position at which to insert an accessory into the immobilization mold, the accessory including at least one of a tensioner, an anchoring mechanism, a sensor, a probe, or a treatment application device;

determine a third portion about the position within the three-dimensional mold model corresponding to dimensions of the accessory to be inserted; and

remove the third portion from at least a part of the second portion of the three-dimensional mold model for insertion of the accessory.

3. The system of claim 1 , further comprising an accessory positioner executable on the computing system, configured to

identify, within the three-dimensional mold model, a position at which to insert an accessory into the immobilization mold, the accessory including at least one of a tensioner, an anchoring mechanism, a sensor, a probe, or a treatment application device;

determine a third portion about the position within the three-dimensional mold model corresponding to dimensions of the accessory to be inserted; and

add the third portion to the three-dimensional mold model for insertion of the accessory.

4. The system of claim 1 , wherein the mold model generator is further configured to generate the three-dimensional mold model by:

identifying a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space; and

for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space:

identifying a first section and a second section to divide the opening about the first axis;

determining a first global extremum from the first section and a second global extremum from the second section within the opening relative to the second axis; and

removing, from the three-dimensional mold, the first portion in the first section from the first global extremum relative to the first axis and the first portion in the second section from the second global extremum relative to the first axis.

5. The system of claim 1 , wherein the mold model generator is further configured to generate the three-dimensional mold model by:

identifying a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space; and

for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space:

identifying a first section and a second section to divide the opening about the first axis;

determining a first plurality of extrema in the first section within the opening and a second plurality of extrema in the second section within the opening relative to the second axis;

identifying, in the first section, a first inward protrusion of the one or more inward protrusions in the three-dimensional mold model at the two-dimensional slice based on the first plurality of extrema;

identifying, in the second section, a second inward protrusion of the one or more inward protrusions in the three-dimensional mold model at the two-dimensional slice based on the second plurality of extrema; and

remove the first inward protrusion and the second inward protrusion from the two-dimensional slice of the three-dimensional mold model.

6. The system of claim 1 , wherein the mold model generator is further configured to generate the three-dimensional mold model by:

identifying a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space;

identifying, for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space, one or more contiguous portions of the opening defined by subtracting the second composite space corresponding to the three-dimensional scan of the subject; and

identifying, for each contiguous portion, a first section and a second section to divide the contiguous portion to remove the first portion and one or more inward protrusions.

7. The system of claim 1 , further comprising a mold model optimizer executable on the computing system configured to:

identify a manufacturing modality of a mold generator to manufacture the immobilization mold in accordance with the three-dimensional model, the manufacturing modality including at least one of a subtractive manufacturing or an additive manufacturing; and

modify the three-dimensional mold model based on the identified manufacturing modality of the mold generator.

8. The system of claim 1 , further comprising a mold model optimizer executable on the computing system configured to apply an image processing technique to the three-dimensional mold model after subtracting the second composite space and removing the first portion and the one or more inward protrusions, the image processing technique including at least one of an autofix function, a smoothing filter, a mesh reduction function, or a depth contrast adjustment.

9. The system of claim 1 , wherein the mold model generator is further configured to provide the three-dimensional mold model to a mold generator device to manufacture the immobilization mold in accordance with the three-dimensional mold model.

10. The system of claim 1 , further comprising:

an imager interface executable on the computing system configured to acquire, from an imaging device, the three-dimensional scan of the subject; and

an image converter executable on the computing system configured to convert the three-dimensional scan of the subject to the second composite space to subtract from the first composite space of the three-dimensional mold model.

11. A method of processing immobilization molds for application of treatment, comprising:

generating, by a computing system having one or more processors, a three-dimensional mold model of immobilization mold within with a subject is to be positioned for application of a treatment, the three-dimensional dimensional mold model generated by:

subtracting, from a first composite space of the three-dimensional mold model, a second composite space corresponding to a three-dimensional scan of at least a portion of the subject to define an opening within the three-dimensional mold model;

removing, from the three-dimensional mold model, to define an imprint in the opening, a first portion along a first axis in which the subject is to enter the immobilization mold;

identifying, from a second portion of the three-dimensional mold model remaining after the removal of the first portion, one or more inward protrusions into the imprint of the three-dimensional mold model relative to a second axis intersecting the first axis; and

removing, from the three-dimensional mold model, the identified one or more inward protrusions relative to the second axis.

12. The method of claim 11 , further comprising:

identifying, by the computing system, within the three-dimensional mold model, a position at which to insert an accessory into the immobilization mold, the accessory including at least one of a tensioner, an anchoring mechanism, a sensor, a probe, or a treatment application device;

determining, by the computing system, a third portion about the position within the three-dimensional mold model corresponding to dimensions of the accessory to be inserted; and

removing, by the computing system, the third portion of at least a part of the second portion of the three-dimensional mold model for insertion of the accessory.

13. The method of claim 11 , further comprising:

identifying, by the computing system, within the three-dimensional mold model, a position at which to insert an accessory into the immobilization mold, the accessory including at least one of a tensioner, an anchoring mechanism, a sensor, a probe, or a treatment application device;

determining, by the computing system, a third portion about the position within the three-dimensional mold model corresponding to dimensions of the accessory to be inserted; and

adding, by the computing system, the third portion to the three-dimensional mold model for insertion of the accessory.

14. The method of claim 11 , wherein generating the three-dimensional mold further comprises:

identifying, by the computing system, a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space; and

for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space:

identifying, by the computing system, a first section and a second section of to divide the opening about the first axis;

determining, by the computing system, a first global extremum from the first section and a second global extremum from the second section within the opening relative to the second axis; and

removing, by the computing system, from the three-dimensional mold, the first portion in the first section from the first global extremum relative to the first axis and the first portion in the second section from the second global extremum relative to the first axis.

15. The method of claim 11 , wherein generating the three-dimensional mold further comprises:

identifying, by the computing system, a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space; and

for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space:

identifying, by the computing system, a first section and a second section to divide the opening about the first axis;

determining, by the computing system, a first plurality of extrema in the first section within the opening and a second plurality of extrema in the second section within the opening relative to the second axis;

identifying, by the computing system, in the first section, a first inward protrusion of the one or more inward protrusions in the three-dimensional mold model at the two-dimensional slice based on the first plurality of extrema;

identifying, by the computing system, in the second section, a second inward protrusion of the one or more inward protrusions in the three-dimensional mold model at the two-dimensional slice based on the second plurality of extrema; and

removing, by the computing system, the first inward protrusion and the second inward protrusion from the two-dimensional slice of the three-dimensional mold model.

16. The method of claim 11 , wherein generating the three-dimensional mold further comprises:

identifying, by the computing system, a plurality of two-dimensional slices of the three-dimensional mold model after subtracting the second composite space;

identifying, by the computing system, for each two-dimensional slice of the three-dimensional mold model after subtracting the second composite space, one or more contiguous portions of the opening defined by subtracting the second composite space corresponding to the three-dimensional scan of the subject; and

identifying, by the computing system, for each contiguous portion, a first section and a second section to divide the contiguous portion to remove the first portion and one or more inward protrusions.

17. The method of claim 11 , further comprising identifying, by the computing system, a manufacturing modality of a mold generator to manufacture the immobilization mold in accordance with the three-dimensional model, the manufacturing modality including at least one of a subtractive manufacturing or an additive manufacturing; and

modifying, by the computing system, the three-dimensional mold model based on the identified manufacturing modality of the mold generator.

18. The method of claim 11 , further comprising

applying, by the computing system, an image processing technique to the three-dimensional mold model after subtracting the second composite space and the removal the first portion and the one or more inward protrusions, the image processing technique including at least one of an autofix function, a smoothing filter, a mesh reduction function, or a depth contrast adjustment.

19. The method of claim 11 , further comprising

providing, by the computing system, the three-dimensional mold model to a mold generator device to manufacture the immobilization mold in accordance with the three-dimensional mold model.

20. The method of claim 11 , further comprising

acquiring, by the computing system, from an imaging device, the three-dimensional scan of the subject; and

converting, by the computing system, the three-dimensional scan of the subject to the second composite space to subtract from the first composite space of the three-dimensional mold model.