INDIVIDUALLY TAILORED SOFT COMPONENTS

• US 20120232857A1
• Filed: 10/06/2010
• Published: 09/13/2012
• Est. Priority Date: 10/16/2009
• Status: Abandoned Application

• Current Assignee: 3shape A/S
• Original Assignee: 3shape A/S
• Inventors: Fisker, Rune, McLeod, Ialn
• Application Number:
  US13/502,296
• Publication Number:
  US 20120232857A1
• Time in Patent Office: Days
• US Class Current: 703/1
• CPC Class Codes: B29C 33/3835 Designing moulds, e.g. using CAD-CAM
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/448 destructible B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: H04R 25/652 Ear tips; Ear moulds hybrid ear moulds or post-processing thereof for their customisation H04R25/659
• CPC Class Codes: H04R 25/658 Manufacture of housing parts

Abstract

A computer-implemented method for creating a customized CAD model of a casting mold, defined as the casting mold CAD model, for moulding of a personalized device, where the casting mold is used for casting an at least partly soft mould as part of the personalized device, and where the casting mold is adapted to be manufactured by means of rapid prototyping, such as 3D printing, including the steps of: —acquiring an input 3D model representing the personalized device, where the input 3D model is acquired by means of 3D scanning, —generating the casting mold CAD model as an impression of at least a part of the input 3D model, said casting mold CAD model thereby including the negative geometry of the personalized device, and—defining at least one sectioning of the casting mold CAD model by means of at least one separation plane and/or separation spline.

Claims

1-36. -36. (canceled)

37. A computer-implemented method for creating a customized CAD model of a casting mold, defined as the casting mold CAD model, for moulding of a personalized device, where the casting mold is used for casting an at least partly soft mould as part of the personalized device, and where the casting mold is adapted to be manufactured by means of rapid prototyping, such as 3D printing, said method comprising the steps of:

acquiring an input 3D model representing the personalized device, where the input 3D model is acquired by means of 3D scanning,

generating the casting mold CAD model as an impression of at least a part of the input 3D model, said casting mold CAD model thereby comprising the negative geometry of the personalized device, and

defining at least one sectioning of the casting mold CAD model by means of at least one separation plane and/or separation spline.

38. A method according to claim 37, further comprising the step of providing an interlocking mechanism of the casting mold CAD model.

39. A method according to claim 37, wherein the personalized device is shaped to fit an anatomic part of person.

40. A method according to claim 37, further comprising the step of acquiring one or more 3D models of

at least a part of said anatomic part, and/or

an impression of said anatomic part, and

wherein the input 3D model is based on said one or more 3D-models.

41. A method according to claim 40, wherein said one or more 3D models are provided by 3D scanning said anatomic part and/or by 3D scanning an impression of said anatomic part.

42. A method according to claim 37, wherein said at least one separation plane and/or separation spline is defined at the input 3D model.

43. A method according to claim 37, further comprising the step of automatically arranging said at least one separation plane and/or separation spline, preferably based on one or more algorithms for a best fit.

44. A method according to claim 37, wherein said at least one separation plane and/or separation spline is arranged to remove undercuts.

45. A method according to claim 37, further comprising the step of selecting and/or generating one or more template casting mold CAD models.

46. A method according to claim 37, wherein the casting mold CAD model is generated from a template CAD model.

47. A method according to claim 37, wherein the casting mold CAD model and/or the template casting mold CAD model comprises a plurality of interlocking geometry section models that are adapted to assemble to an enclosed casting mold model.

48. A method according to claim 37, wherein the personalized device is a soft ear mold, the anatomic part is the human ear and the 3D model is a model of the human ear and/or the human ear canal and/or a model of an impression of the human ear and/or the human ear canal.

49. A method according to claim 37, wherein the casting mold CAD model and/or the template casting mold CAD model is defined by means of a plurality of configuration parameters, and where the configuration parameters of a casting mold CAD model and/or a template casting mold CAD model are selected from one or more of the following parameters:

number of interlocking sections,

type of casting mold housing, such as open or enclosed casting mold,

the width of the wall of the casting mold,

configuration of interlocking mechanism,

number, dimension and location of leg stanchions for the casting mold,

type and location of one or more identification elements,

connector strand dimensions between casting mold sections,

locking mechanism dimensions between casting mold sections.

50. A method according to claim 37, further comprising the step of defining and positioning at least one injection point in the casting mold CAD model, said at least one injection point being adapted for pouring and/or injection of soft material in the casting process.

51. A method according to claim 37, further comprising the step of defining and positioning at least one drainage hole in the casting mold CAD model, said at least one drainage hole being adapted for the release of excess soft material during the casting process.

52. A method according to claim 50, wherein said positioning is provided manually or automatically or as a combination hereof.

53. A method according to claim 37, further comprising the step of minimizing the amount and/or volume of necessary material for the casting mold CAD model.

54. A method for producing a soft cast for a personalized device, a device such as an ear mold hearing aid device, said method comprising the steps of:

designing a casting mold CAD model according to claims 37,

3D printing a casting mold based on said casting mold CAD model,

injection and/or pouring of soft material into the casting mold,

assembling the different sections of the casting mold containing the soft material thereby producing the soft cast, and

extracting the cast from the casting mold by;

disassembling each interlocked cast section, and/or

breaking the cast along one or more of the fragile lines.

55. A computer program product having a computer readable medium, said computer program product providing a system for creating a customized CAD model of a casting mold for molding of a personalized device, and said computer program product comprising means for carrying out all of the steps of the method according to claim 37.

56. A system for creating a customized CAD model of a casting mold, defined as the casting mold CAD model, for molding of a personalized device, where the casting mold is used for casting an at least partly soft mould as part of the personalized device, and where the casting mold is adapted to be manufactured by means of rapid prototyping, such as 3D printing, said system comprising:

means for acquiring an input 3D model representing the personalized device, where the input 3D model is acquired by means of 3D scanning, and

means for generating the casting mold CAD model comprising;

an impression of the input 3D model, said casting mold CAD model thereby comprising the negative geometry of the personalized device, and

at least one separation plane and/or separation spline defining the sectioning of the casting mold CAD model.