PROSTHESIS CASTING SYSTEM

Abstract

A scanning apparatus (5) for scanning a body part (40) comprises a container (10) configured to receive the body part and capable of holding a pressurised liquid. By such provision, in circumstances where it may be advantageous to use a pressurised liquid, rather than a pressurised gas, the apparatus (5) may be capable of scanning the body part under pressure using a pressurised liquid. In another embodiment a scanning apparatus (10) for scanning a body part comprises a container (70) configured to receive the body part and to receive a flow of fluid, wherein the container (70) comprises a longitudinal axis along which the cross-section of the container changes. In another embodiment a scanning apparatus (10) for scanning a body part comprises a collapsible container (80) configurable to receive the body part and to receive a first fluid.

Claims

1-64. (canceled)

65. A scanning apparatus for scanning a body part, the scanning apparatus comprising: a container configured to receive the body part and capable of holding a pressurised liquid.

66. The scanning apparatus of claim 65, wherein, in use, the container is arranged to receive a pressurised liquid and/or a pressurised gas.

67. The scanning apparatus of claim 66, wherein the pressurised fluid is configurable to apply pressure to or on at least a portion of the body part.

68. The scanning apparatus of claim 66, wherein the pressurised gas comprises air.

69. The scanning apparatus of claim 66, wherein the pressurised liquid comprises water.

70. A scanning apparatus for scanning a body part, the scanning apparatus comprising: a collapsible container configurable to receive the body part and to receive a first fluid.

71. The scanning apparatus of claim 70, wherein, in use, the first fluid is configured to apply pressure to or on at least a portion of the body part.

72. The scanning apparatus of claim 70, wherein the collapsible container is configurable between at least a collapsed configuration and an extended/deployed configuration.

73. The scanning apparatus of claim 70, wherein the collapsible container is at least partially flexible.

74. The scanning apparatus of claim 70, the scanning apparatus comprising a frame, wherein the frame is deployable between a first or stowed configuration and a second or deployed configuration.

75. The scanning apparatus of claim 70, wherein the collapsible container is at least partially inflatable and/or the collapsible container is concertinaed.

76. The scanning apparatus of claim 65, the scanning apparatus comprising at least one of: a laser line scanner, a stereo vision scanner, a photogrammetry scanner, and/or a structured light scanner.

77. The scanning apparatus of claim 65, wherein the container comprises sealing means, wherein in use the sealing means at least partially seals the container around or against the body part.

78. The scanning apparatus according to claim 65, the scanning apparatus comprising scales, wherein the scales are configured to measure or determine a weight, such as body weight, exerted through the body part.

79. The scanning apparatus of claim 65, the scanning apparatus comprising a socket shape, wherein the socket shape comprises markers, and wherein socket shape is shaped to correspond to the shape of at least one of: the inner thigh; the groin; the pelvis; the ischial tuberosity; and/or the greater trochanter.

80. A scanning apparatus for scanning a body part, the scanning apparatus comprising: a container configured to receive the body part and to receive a flow of fluid, wherein the container comprises a longitudinal axis along which the cross-section of the container changes.

81. The scanning apparatus of claim 80, wherein, in use, the flow of fluid and/or the container is/are configured to apply pressure to or on at least as a portion of the body part.

82. The scanning apparatus of claim 80, wherein the container comprises or defines a venturi container.

83. The scanning apparatus of claim 80, wherein the scanning apparatus is configured to scan the body part to determine shape and/or topography of the body part.

84. A method of scanning a body part, the method comprising: receiving the body part in a collapsible container, pressurising a first fluid around the body part, and scanning the body part.

85. A method of scanning a body part, the method comprising: flowing fluid along the body part, and scanning the body part.

86. The method of claim 85, the method comprising providing or applying a pressure gradient along the body part.

87. The method of claim 85, the method comprising using the venturi effect to control the pressure of the flowing fluid.

88. A computer file, the computer file comprising a scan of a body part, the scan having been made with the scanning apparatus of claim 65 and/or with the method of claim.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0167] FIG. 1 shows a scanning apparatus for use with pressurised liquid;

[0168] FIG. 2 shows a scanning apparatus in use;

[0169] FIG. 3 shows another scanning apparatus for use with pressurised liquid;

[0170] FIG. 4 shows a scanning apparatus for use with a flow of fluid;

[0171] FIG. 5 shows a collapsible scanning apparatus;

[0172] FIG. 6 shows an embodiment of a scanning apparatus according to the present invention;

[0173] FIG. 7 shows another embodiment of a scanning apparatus according to the present invention;

[0174] FIG. 8 shows another embodiment of a scanning apparatus according to the present invention FIG. 9 shows another embodiment of a scanning apparatus according to the present invention;

[0175] FIG. 10 shows another embodiment of a scanning apparatus according to the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0176] FIG. 1 shows different views of a scanning apparatus 5. The scanning apparatus 5 comprises a laser projector 21 and a camera 22 which are both mounted on a rotating frame 11. The scanning apparatus 5 comprises a container 10 and a pumping system 13 to pressurize the contents of the container 10. The number of laser projectors 21 and cameras 22 may be increased to reduce the time required to perform a scan, or may be reduced to reduce the cost of the scanning apparatus 5. The scanning apparatus 5 includes an adjustable mechanism 15. The adjustable mechanism 15 can be used to raise or lower the scanning apparatus 5 for use by different users which helps the user to stay stationary and level while their body part is correctly positioned in the container 10. The container 10 comprises an opening 12. The opening 12 can be adjusted around the body part of a user, to seal the container 10 when a user's body part is inserted into the container 10, and may comprise, e.g., a latex barrier or an inflatable bladder. The fluid (liquid or gas) in the container 10 can then be pressurised with the pump 13 via the pipe 14 to pressurise the soft tissue of the body part. This simulates the loaded condition of the body part and minimises further modification of the captured shape.

[0177] FIG. 2a shows the scanning apparatus 5 of FIG. 1 being used by a user 1. The user's 1 residual leg is placed in the container 10. The opening 12 is sealed around the user's 1 residual leg. To perform a scan, the laser projector 21 projects a single vertical line through the container 10 on to the residual leg, and the camera 22 captures an image of the projected line on the surface of the leg. Alternatively, the laser projector 21 may project multiple parallel lines or even a pattern if one uses structured light or photogrammetry. In an alternative embodiment, UV light may be used, for example when using a stereo vision system.

[0178] The frame 11 rotates around the container 10, and the camera 22 captures images of the projected line from the laser projector 21 as the frame 11 moves around the container 19. The frame rotates 360 around the container. Images are collected 360 around the residual leg. Image processing software processes each captured image to determine the depth of surface within the line projected from the laser projector 21. By analysing all the images, it is possible to create a 360 computer model of the residual leg. It will be appreciated by one skilled in the art that the speed of the scan can be increased by increasing the number of laser projectors 21 and cameras 22 around the container 10.

[0179] FIG. 2b shows a scanning apparatus 5 being used by a user. As before, the residual leg 40 is placed in the container 10 and scanned. This scanning apparatus 5 additionally includes secondary cameras 30a-c and secondary light sources 35a-c which scan the intact leg 45. The secondary light sources 35a-c projects light onto the intact leg 45. The secondary cameras 30a-c scan the intact leg 45 while the light from the secondary light sources 35a-c is projected onto the intact leg 45. The intact leg 45 may be scanned using any of the methods of scanning the residual leg 40. The scan of the intact leg 45 can be used to match the design of the prosthetic for the residual leg 40 to the appearance (shape, size, colour, etc) of the intact leg 45.

[0180] The scanning apparatus 5 comprises scales 50. By monitoring both pressure and body weight (using scales 50), body weight and pressure can be correlated and/or converted one to the other.

[0181] FIG. 3 shows a scanning apparatus 55 comprising a fixed frame 31 and number of cameras 32 around a container 10. A user's body part is placed in the container 10 for scanning. The container 10 is sealed, and the fluid (liquid or gas) within is pressurised. When using photogrammetry, the cameras 32 are triggered simultaneously to scan the body part. Because all cameras 32 are triggered simultaneously, a snap shot of the body part at a particular moment in time is captured. This increases the accuracy of the resulting model, as the body part cannot move between the capture of different images.

[0182] FIG. 4 shows a container 65 for use in a scanning apparatus. The walls of the container 65 are concave, such that the diameter of the container 65 decreases from the top 66 of the container 65 to the middle 67 of the container 65, and the diameter of the container 65 increases from the middle 67 of the container 65 to the bottom 68 of the container 65. In use, a residual limb 40 is placed in the container 65. An air flow 70 is passed through the container 65 from the top 66 of the container 65 to the bottom 68 of the container. Due to the change in the diameter of the container 65 along the direction of air flow 70, the air pressure inside the container 65 changes along the direction of air flow 70. Without wishing to be bound by theory, it is believed that the container 65 may act as a venturi and/or may provide a venturi effect. The top 66 and bottom 68 of the container 65 experience a higher air pressure, and the middle 67 of the container 65 experiences a lower pressure. By controlling the shape of the container 65 it is therefore possible to control the air pressure along the direction of air flow 70 within the container 65. This means that the pressurisation of the soft tissue of the residual leg 40 can be controlled. This in turn means that the loaded conditions which would be experienced by the residual leg 40 when using a prosthetic can be more accurately reproduced within the container 65, and so the scan of the residual leg 40 can be used to produce a more accurate and comfortable prosthetic.

[0183] FIGS. 5a-c show a collapsible container 80 for use in a scanning apparatus. The scanning apparatus comprises two rings of alternating light sources 21 and cameras 22. These rings are stacked one above the other. The rings and/or the light sources 21 and cameras 22 are supported by a frame (not shown). The residual leg 40 is placed within the rings, above the collapsed container 80a. The collapsible container 80b is then extended/deployed over the residual leg 40 and the rings of light sources 21 and cameras 22. Once the collapsible container 80c is fully extended over the residual leg 40, the top of the collapsible container 80c is sealed, which in this embodiment is carried out by use of a draw string 85. It will be appreciated that, in other embodiments not depicted here merely for conciseness, the seal may be comprise or may consist of a latex barrier or an inflatable bladder. The first volume of the collapsible container 80c can then be pressurised. The first volume is pressurised by the body weight of the user through the residual leg 40.

[0184] FIG. 6 shows a scanning apparatus 5 configured to scan a user's body part using stereo vision. The scanning apparatus 5 comprises a container 10. The container 10 comprises an opening 12. The opening 12 can be adjusted around the body part of a user, to seal the container 10 when a user's body part is inserted into the container 10. The scanning apparatus 5 comprises a first camera 22a and a second camera 22b, which are both mounted on a rotating frame 11. The container 10 is transparent, such that the cameras 22a-b can image the contents of the container 10, for example a user's body part which is inserted into the container 10.

[0185] The cameras 22a-b are both directed towards the longitudinal axis of the container 10. The two cameras 22a-b are horizontally displaced from each other. To perform stereo vision scanning, the two cameras 22a-b each simultaneously capture an image, for example each camera 22a-b captures an image of a user's body part inserted into the container 10. The fields of view of the cameras 22a-b overlap. Consequently, the two cameras 22a-b capture overlapping images of the body part from different angles. Due to the different angles at which the images of the body part are captured, stereo vision analysis can be performed on the two images of the body part, to determine depth information, similar to binocular depth perception in human vision. From the determined depth perception, it is possible to create a 3D model of the body part using stereo vision from the captured images of the body part.

[0186] The frame 11 may rotate around the container 10. The cameras 22a-b may therefore scan other portions of the body part, of the cameras 22a-b may scan completely around the body part, which would allow a full 3D model of the body part to be created.

[0187] FIG. 7 shows a scanning apparatus 5 configured to scan a user's body part using stereo vision, very similar to the scanning apparatus of FIG. 6. The scanning apparatus 5 comprises a container 10 with an opening 12. A first pair of cameras 22a-b are mounted on a first rotating frame 11a. Additionally, a second pair of cameras 23a-b are mounted on a second rotating frame 11b. The first pair of cameras 22a-b and the second pair of cameras 23a-b are both configured to capture images for stereo vision scanning. The use of two pairs of cameras allows for faster scanning. The use of two pairs of cameras also allows a larger area of the body part to be scanned simultaneously. Where only one pair of cameras is used, the images of different portions of the body part cannot be captured simultaneously, and so the body part may move between image captures. The use of two pairs of cameras, which can capture images simultaneously, can therefore create a higher quality 3D model, as the body part cannot move between image captures.

[0188] FIG. 8 shows a plurality of cameras 22 configured to scan a user's body part using photogrammetry. There are twelve cameras 22 mounted on a frame 11. The rest of the scanning apparatus, for example the container, are omitted from FIG. 8 for clarity, such that the cameras 22 and the frame 11 can clearly be seen. The frame 11 and the cameras 22 may be inside or outside the container.

[0189] The cameras 22 are mounted on the frame 11 in a lower ring of six cameras 22 and an upper ring of six cameras 22. The cameras 22 are all directed towards the longitudinal axis of the frame 11. The cameras 22 are arranged such the cameras 22 can simultaneously capture images from all sides of a user's body part that is placed along the longitudinal axis of the frame 11. As the body part is imaged from all sides, the captured images can be combined using photogrammetry techniques to create a complete 360 3D model of the body part.

[0190] FIG. 9 shows a plurality of laser line scanners configured to scan a user's body part. Each laser scanner comprises a laser projector 21a-f and a camera 22a-f. The laser projectors 21a-f and the cameras 22a-f are mounted on a frame 11. As in FIG. 8, the rest of the scanning apparatus, for example the container, are omitted from FIG. 9 for clarity, such that the laser projectors 21a-f, the cameras 22a-f and the frame 11 can clearly be seen. The frame 11 and the laser line scanners may be inside or outside the container. The laser projectors 21a-f and the cameras 22a-f are directed towards the longitudinal axis of the frame.

[0191] To perform a scan, each laser projector 21a-f projects a vertical line on to a user's body part, and each corresponding camera 22a-f captures an image of the projected line on the surface of the body part. The captures images of the laser lines are analysed to determine the topography of the body part. The frame 11 is rotated around the body part. By rotating the frame 11, the laser projectors 21a-f can project a laser line onto different parts of the body part, and corresponding images can be captured. By rotating the frame like this, it is possible to laser line scan completely around the body part, from which a 3D model of the body part can be created.

[0192] It is difficult to perform transfemoral scans, because it is difficult to scan the proximal structure in the pelvis and femur, such as the ischial tuberosity and the greater trochanter. For example, it is difficult to arrange a laser projector and camera between a user's thighs. One possible solution to this problem is to use socket shapes, as shown in FIG. 10.

[0193] FIG. 10 shows a scanning apparatus 5 configured to scan a user's body part using stereo vision. The scanning apparatus 5 comprises a container 10. The scanning apparatus 5 comprises a first camera 22a and a second camera 22b, which are both mounted on a rotating frame 11. The container 10 is transparent, such that the cameras 22a-b can image the contents of the container 10, for example a user's body part which is inserted into the container 10. The container 10 and frame 11 are mounted on an adjustable mechanism 15. The adjustable mechanism 15 can be used to raise or lower the scanning apparatus 5 for use by different users which helps the user to stay stationary and level while their body part is correctly positioned in the container 10.

[0194] The scanning apparatus 10 includes a socket shape 105. The socket shape 105 is mounted on a support 110, and the support 110 is attached to the container 10 with an adjustable attachment 115. The socket shape 105 can be raised or lowered be raising or lowering the support 110 through the adjustable attachment 115. The socket shape 105 includes markers 120a-c.

[0195] In use, a user would place their residual leg (not shown) in the container. A socket shape corresponding to the shape of the area of the thigh which could not be scanned would be chosen. For example, the socket shape could have a shape corresponding to the shape of the ischial tuberosity. The socket shape would be extended into contact with the area of the user which could not be scanned. The shape of the socket shape would be such that the socket shape would cup the area of the user which could not be scanned.

[0196] During the scan, the markers 120a-c on the socket shape 105 would be identified. The position of the markers 120a-c in space relative to the residual leg would then be used to determine the 3D position and orientation of the socket shape in space relative to the residual leg. As the socket shape 105 cups the area of the thigh which cannot be scanned, and the shape, position and orientation of the socket shape 105 are known, it is possible to know the shape, position and orientation of the area of the thigh which cannot be scanned. The shape, position and orientation of the area of the thigh which cannot be scanned can then be included in the 3D model of the residual leg. The 3D model of the residual leg is generated from the scanned parts of the residual leg and from the determined shape, position and orientation of the area of the residual leg which cannot be scanned.