PROCESS FOR MANUFACTURING ANATOMICAL MODELS

Abstract

A process for the manufacture of anatomical models which, from images obtained and the creation of editable and printable files, includes a sub-process for generating main moulds, a sub-process for generating internal elements, a sub-process for positioning the internal elements which when these include soft elements comprises a step of reversible stiffening, a sub-process for integrating the internal elements comprising a step of pouring of parenchyma and an demoulding step and a post-processing sub-process.

Claims

1-19. (canceled)

20. A method for the manufacture of anatomical models of the type comprising the capturing of one or more images, using and processing of such images to select (or segment) different elements of an anatomical structure of interest from the images obtained, obtaining one or more editable computer files for the subsequent creation, and using 3D printing of elements of the anatomical model and moulds for its total or partial manufacture, comprising: 1. a sub-process for generating main moulds comprising modelling of a virtual path of auxiliary positioning elements and their relationship with the main mould, calculating a cross-section and length of these auxiliary positioning elements, a step for discriminating by size between large parts and small parts and a step for creating the mould; 2. a sub-process for generating internal elements comprising modelling the virtual path of the auxiliary positioning elements and their relationship with the internal element, calculating a cross-section and length of such elements, a step for discriminating between rigid elements and soft elements, a step for discriminating by size between large parts and small parts, and in the case of soft parts, a step for generating secondary moulds, a step of pouring filling material and an demoulding step; 3. a sub-process for positioning the internal elements, which when it includes soft elements comprises a step of reversible stiffening; 4. a sub-process for integrating the internal elements comprising a step of pouring of parenchyma and a demoulding step; and 5. a post-processing sub-process.

21. The method according to claim 20, wherein in the case of the large parts of sub-processes 1 and 2, further comprising a step for creating the mould, whether a main mould or a secondary mould, wherein the mould is printed with a thickness between 2 mm and 15 mm

22. The method according to claim 21, wherein the mould, whether main or secondary, is printed in PLA.

23. The method according to claim 3, wherein an additive is also applied to the inner face of the main mould in order to smooth out the inner surface.

24. The method according to claim 20, wherein the sub-process for generating main moulds and the sub-process for generating internal elements comprise, in the case of small parts, a step for creating the mould comprising the prototyping of the element in positive, immersing it in silicone, curing the silicone and removing the prototype.

25. The method according to claim 20, wherein the sub-process for generating internal elements, in the case of rigid elements, comprises the printing thereof.

26. The method according to claim 20, wherein the sub-process for positioning internal elements comprises fastening the auxiliary positioning elements to the internal elements and the main mould.

27. The method according to claim 20, wherein the step for reversible stiffening of the sub-process for positioning internal elements comprises freezing the soft internal elements.

28. The method according to claim 20, wherein the pouring step comprises the introduction, into the main or secondary mould, of the previously refrigerated pouring material.

29. The method according to claim 28, wherein the pouring material is refrigerated to 5° C. in a cooling step prior to pouring.

30. The method according to claim 28, wherein the pouring step also comprises a step for subjecting the pouring material to a vacuum prior to pouring.

31. The method according to claim 28, wherein in the pouring step, the pouring is performed at atmospheric pressure and also comprises, after pouring, a curing step in a reboiler at a pressure of 70 psi and at a controlled temperature of more than 25° C.

32. The method according to claim 22, wherein the demoulding step, when the main or secondary mould is made in PLA, comprises heating the assembly to a temperature between 60° C. and 100° C.

33. The method according to claim 32, wherein the heating is performed by subjecting the assembly to the action of a heated fluid.

34. The method according to claim 32, wherein the fluid is water.

35. The method according to claim 20, wherein the demoulding step of the sub-process for integrating the internal elements also comprises extracting any through auxiliary positioning elements and filling the holes of the spaces they occupied.

36. The method according to claim 35, wherein the filling of the holes produced by the auxiliary positioning elements is performed with the pouring material.

37. The method according to claim 20, wherein the post-processing sub-process comprises buffing to remove imperfections and to smooth out surfaces and the application of a protective lacquer.

38. The method according to claim 20, wherein the pouring material comprises urethane rubber.

Description

DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

[0080] Described below is an embodiment of the invention that is neither unique nor limiting but merely explanatory.

[0081] The process for manufacturing anatomical models starts by capturing one or more images using common techniques such as CAT (computerised axial tomography), NMR (nuclear magnetic resonance), ultrasound or any other, the processing of such images to select (segment) the different elements of the anatomical structure of interest from the images obtained and obtaining one or more editable computer files.

[0082] Having obtained the editable images, the manufacturing process of anatomical models comprises the following sub-processes:

[0083] 1. A sub-process for generating the main moulds.

[0084] 2. A sub-process for generating the internal elements.

[0085] 3. A sub-process for positioning the internal elements.

[0086] 4. A sub-process for integration of the internal and external elements.

[0087] 5. A post-processing sub-process.

[0088] The sub-process for generating the main moulds includes the following steps:

[0089] Computer modelling of the editable images until obtaining a file that is compatible with 3D printing. The computer modelling comprises not only the shape itself of the anatomical model to be manufactured, but also the modelling of the auxiliary positioning elements, which implies their housings (anchors, rest areas, supports, and position openings) and the openings for the pouring nozzles through which the parenchyma will be poured or injected, as well as determining the cross-section and length of the auxiliary positioning elements.

[0090] In the step for discriminating by size, since we intend to manufacture a large piece, we choose to print the mould.

[0091] Printing the mould in PLA. This main mould has a thickness of 2 millimetres, which makes it more like a sheath than a conventional mould. This allows saving on material, time and ease of demoulding for any geometry.

[0092] Application of an additive on the inner face of the moulds to smooth out the surface.

[0093] The sub-process for the generation of internal elements, in this case soft internal elements, includes the following steps:

[0094] Computer modelling of the editable images until obtaining a file that is compatible with 3D printing. The computer modelling comprises not only the shape of the part to be manufactured, but also the housings (anchors, resting areas, supports or positioning openings) for the auxiliary positioning elements and the openings for the pouring nozzles through which the filling material shall be poured or injected.

[0095] Since we intend to manufacture a small part, when discriminating by size we have chosen to obtain a secondary mould through the following sub-steps:

[0096] Prototyping of the internal elements in positive by printing in ABS.

[0097] Immersion of the printed prototype in silicone and removal of the prototype to obtain the secondary mould.

[0098] Adding the pouring nozzles to the mould.

[0099] Sealing the mould.

[0100] Pouring of the filling material. The filling material has previously been subjected to a vacuum operation outside the mould in order to be subsequently poured at atmospheric pressure into the mould.

[0101] The filling material is silicone.

[0102] Demoulding.

[0103] The sub-process for positioning the internal elements includes the following steps:

[0104] Obtaining auxiliary positioning elements, in this case metal rods with a predetermined cross-section and length from modelling the virtual path of the auxiliary positioning elements.

[0105] A stiffening step of the internal elements using a reversible process, in this case freezing, in order to provide the sufficient stiffness as to be able to place them with the rods.

[0106] Fastening of the internal elements to the rods and of the latter to the main moulds pursuant to the positioning calculated in the computer modelling of the virtual path.

[0107] The sub-process for integration of the internal and external elements comprises the following steps:

[0108] Closing of the main moulds with the internal elements already positioned inside.

[0109] Pouring of the parenchyma material through the pouring nozzles, in this case this comprises urethane rubber. To do this such material is subjected to a prior cooling to 5° to slow down its curing. After such prior cooling the parenchyma material is subjected to a vacuum operation under a vacuum hood and is subsequently removed from it and poured at atmospheric pressure into the main mould.

[0110] The curing is performed in a reboiler with controlled temperature at more than 25° C.

[0111] Once the parenchyma has cured the entire assembly is heated with water at 70° C. for a subsequent demoulding and removal of the rods.

[0112] Once the rods have been removed the holes are filled with the same parenchyma material used.

[0113] A post-processing sub-process.

[0114] After demoulding there is a post-processing sub-process comprising:

[0115] Buffing to remove imperfections and to smooth out surfaces.

[0116] Application of a protective lacquer that also favours transparency.