Single-Action Three-Dimensional Model Printing Methods

• US 20120224755A1
• Filed: 03/02/2011
• Published: 09/06/2012
• Est. Priority Date: 03/02/2011
• Status: Active Grant

• Current Assignee: Andy Wu
• Original Assignee: Andy Wu
• Inventors: Wu, Andy
• Granted Patent: US 8,579,620 B2
• Time in Patent Office: Days
• US Class Current: 382/131
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: G06T 17/00 Three dimensional [3D] modelling, e.g. data description of 3D objects
• CPC Class Codes: G06T 17/20 Finite element generation, e.g. wire-frame surface description, tesselation
• CPC Class Codes: G06T 19/20 Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts
• CPC Class Codes: G06T 2200/04 involving 3D image data
• CPC Class Codes: G06T 2200/08 involving all processing steps from image acquisition to 3D model generation
• CPC Class Codes: G06T 2207/10081 Computed x-ray tomography [CT]
• CPC Class Codes: G06T 2207/30008 Bone
• CPC Class Codes: G06T 2210/41 Medical

Abstract

Methods and techniques of using 3D printers to create physical models from image data are discussed. Geometric representations of different physical models are described and complex data conversion processes that convert input image data into geometric representations compatible with third party 3D printers are disclosed. Printing templates are used to encapsulate complex geometric representations and complicated data conversion processes from users for fast and simple 3D physical model printing applications.

Claims

1. A system for printing a 3D physical model from an image data set, comprising:

a display component for displaying one or more printing templates; and

a single-action data processing component that in response to a single-action selection of a printing template, executes the selected printing template to take the image data set as input, generate a geometric representation for use on a 3D printer.

2. The system of claim 1, wherein the one or more printing templates can be displayed by descriptive text, or by images including graphical icons or 3D renderings, or by a combination of text and images.

3. The system of claim 1, wherein the single-action is a clicking of a mouse button when a cursor is positioned over a predefined area of the displayed one or more printing templates, or a selection of an item from the displayed one or more printing templates.

4. The system of claim 1, wherein the single-action data processing component includes one or more printing templates;

and wherein each printing template includes predefined instructions for identifying voxel categories, generating geometric representation and sending generated representation data to a 3D printer for printing a physical model.

5. The system of claim 1, wherein the image data set has a plurality of voxels, each voxel having an intensity value;

wherein the image data set comprises images of one or more three-dimensional regions obtained using one or more imaging modalities selected from magnetic resonance imaging, computed tomography, ultrasound, X-ray imaging, positron emission tomography, microscopy imaging, simulated image data.

6. The system of claim 1, wherein the printing template is a software program configured to:

identify voxel categories in the image data set using predefined criteria;

generate a geometric representation from the identified voxel categories; and

send the generated representation data to a 3D printer for printing a physical model.

7. The system of claim 6, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models, or a combination of them.

8. The system of claim 1, wherein the 3D printer is a rapid prototyping device for producing physical models directly from digital geometric representations.

9. The system of claim 1, wherein a physical model is generated using the 3D printing process on the 3D printer.

10. A method for printing a 3D physical model from an image data set, comprising:

displaying one or more printing templates;

selecting a printing template by a single-action;

executing the selected printing template to generate a geometric representation; and

sending the generated geometric representation to a 3D printer;

11. The method of claim 10, wherein the displaying of one or more printing templates includes displaying a list of printing templates using descriptive text, or using images such as graphical icons or 3D renderings or a combination of text and images.

12. The method of claim 10, wherein the single-action may be a clicking of a mouse button when a cursor is positioned over a predefined area of the displayed list of printing templates, a sound generated by a user, a depressing of a key on a key pad, a selecting action by using a pointing device, or a selection of a displayed indication.

13. The method of claim 10, wherein the executing printing template comprises:

receiving image data as input;

identifying voxel categories in the image data set;

generating a geometric representation from the identified voxels; and

sending the generated geometric representation to a 3D printer for printing a physical model.

14. The method of claim 13, wherein the image data set has a plurality of voxels, each voxel having an intensity value;

wherein the image data set comprises images of one or more three-dimensional regions obtained using one or more imaging modalities selected from magnetic resonance imaging, computed tomography, ultrasound, X-ray imaging, positron emission tomography, microscopy imaging, simulated image.

15. The method of claim 13, wherein the identifying of voxel categories includes checking one or more voxel attributes against a predefined criteria to identify the voxel categories.

16. The method of claim 13, wherein the generating of a geometric representation includes going through all identified voxels to generate a geometric representation.

17. The method of claim 13, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models, or a combination of them.

18. A printing template method for single-action 3D bone structure printing from CT image data comprising:

receiving a CT image data set as input;

identifying all voxels within a value range of bone tissue in either grayscale or Hounsfield unit;

generating a geometric representation from the identified voxels; and

sending the generated geometric representation to a 3D printer for printing a physical model.

19. The method of claim 18, wherein the CT image data set has a plurality of voxels, each voxel having an intensity value or value in Hounsfield unit;

wherein the image data set comprises images of one or more three-dimensional regions obtained using computed tomography.

20. The method of claim 18, wherein the identifying of voxels includes checking the image attribute of each voxel against a value range for bone tissue to identify if it is part of the bone structure.

21. The method of claim 18, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models or a combination of them.

22. A printing template method of single-action 3D printing of solid body comprising steps of:

receiving an image data set as input;

identifying voxels in empty regions and in regions with tissues or materials;

generating a geometric representation from the identified voxels; and

sending the generated geometric representation to a 3D printer for printing a physical model.

23. The method of claim 22, wherein the image data set has a plurality of voxels, each voxel having an intensity value;

wherein the image data set comprises images of one or more three-dimensional regions obtained using one or more imaging modalities selected from magnetic resonance imaging, computed tomography, ultrasound, X-ray imaging, positron emission tomography, microscopy imaging, simulated image.

24. The method of claim 22, wherein the identifying of voxels includes checking the image attribute of each voxel against a predefined criteria for the empty regions to identify whether the voxel is in an empty region or not.

25. The method of claim 24, wherein the predefined criteria may be one or more value ranges to identify whether the voxel is within the ranges or outside the ranges.

26. The method of claim 22, wherein the identifying of voxels includes checking the image attribute of each voxel against a value range indicating no-tissue to identify no-tissue or empty regions;

wherein voxels that are outside the range are identified as tissue regions.

27. The method of claim 22, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models, or a combination of them.

28. A printing template method for single-action 3D printing of a selected organ part comprising:

receiving an image data set as input;

identifying voxels in the selected organ part by segmenting the image data set using either user selected or automatically generated seed points;

generating a geometric representation data from the identified voxels; and

sending the generated geometric representation to a 3D printer for printing a physical model.

29. The method of claim 28, wherein the image data set has a plurality of voxels, each voxel having an intensity value;

wherein the image data set comprises images of the three dimensional region obtained using one or more imaging modalities selected from magnetic resonance imaging, computed tomography, ultrasound, X-ray imaging, positron emission tomography, microscopy imaging, simulated image.

30. The method of claim 28, wherein the identifying of voxels comprises segmenting the image data using either user selected or automatically generated seed points.

31. The method of claim 28, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models, or a combination of them.

32. A printing template method of single-action 3D printing using user selectable image segmentation methods and one or more adjustable parameters comprising:

receiving an image data set as input;

identifying voxels using a user selected image segmentation method and one or more adjustable parameters;

generating a geometric representation from the identified voxels;

displaying a 3D digital rendering of the geometric representation for a user to adjust image segmentation method and adjustable parameters;

regenerating a geometric representation if the method and parameters have been changed; and

sending the generated geometric representation to a 3D printer for printing a physical model.

33. The method of claim 32, wherein the image data set has a plurality of voxels, each voxel having an intensity value;

wherein the image data set comprises images of one or more three-dimensional regions obtained using one or more imaging modalities selected from magnetic resonance imaging, computed tomography, ultrasound, X-ray imaging, positron emission tomography, microscopy imaging, simulated image.

34. The method of claim 32, wherein the identifying of voxels comprises segmenting the image data using the user selected image segmentation method and the one or more adjustable parameters.

35. The method of claim 32, wherein the geometric representation may be a list of 3D points, a list of 3D contours, a list of 3D polygonal surface models, or a combination of them.