METHOD AND COMPUTER PROGRAM FOR CREATING MANUFACTURING DATA, AND METHOD FOR MANUFACTURING AN ORTHOPEDIC DEVICE

Abstract

The invention relates to a method for creating manufacturing data for manufacturing an orthopedic device, which is producible using the created manufacturing data in an automated manufacturing method, wherein the method comprises the following steps: providing a digital 3D body part model of a body part in a data processing facility, providing at least one digital functional component model of an orthopedic functional component in the data processing facility, which is integratable in an orthopedic device, wherein the digital functional component model contains corresponding component properties of the respective orthopedic functional component, generating at least one digital component interface by means of the data processing facility in dependence on at least one component property of at least one selected digital functional component model of an orthopedic functional component, which is to be integrated into the orthopedic device, wherein the digital component interface includes a receptacle for arranging the at least one selected orthopedic functional component, automatically creating a digital orthopedic model of the orthopedic device to be manufactured based on the 3D body part model and the digital component interface for integration of the orthopedic functional component by means of the data processing facility, and generating the digital manufacturing data from the created digital orthopedic model by means of the data processing facility.

Claims

1. A method for creating manufacturing data for manufacturing an orthopedic device producible using the created manufacturing data in an automated manufacturing method, comprising: providing a digital three dimensional (3D) body part model of a body part in a data processing facility, providing at least one digital functional component model of an orthopedic functional component in the data processing facility, wherein the orthopedic functional component is integratable in an orthopedic device, wherein the at least one functional digital functional component model contains corresponding component properties of the respective orthopedic functional component, generating at least one digital component interface in the data processing facility in dependence on at least one component property of at least one selected digital functional component model of at least one selected orthopedic functional component which is to be integrated into the orthopedic device, wherein the at least one digital component interface includes a receptacle for arranging the at least one selected orthopedic functional component, automatically creating a digital orthopedic model of the orthopedic device to be manufactured based on the 3D body part model and the at least one digital component interface for integration of the orthopedic functional component by the data processing facility, and generating digital manufacturing data from the created digital orthopedic model automatically created by the data processing facility.

2. The method as claimed in claim 1, wherein the 3D body part model is a digital representation of the body part for which the orthopedic device is intended and which was converted into an orthopedic intended shape.

3. The method as claimed in claim 1 wherein a digital orthopedic model is created in a form of a volume model.

4. The method as claimed in claim 1 further comprising selecting a digital mechanical interface from a plurality of provided digital mechanical interfaces in dependence on component properties of the at least one selected digital functional component model of the orthopedic device, wherein a receptacle of the selected digital mechanical interface corresponds to the at least one selected orthopedic functional component.

5. The method as claimed in claim 1 wherein the generated at least one digital component interface is also generated in dependence on the 3D body part model and/or on a digital model, created from the 3D body part model, of the orthopedic device to be manufactured.

6. The method as claimed in claim 1 further comprising, using the data processing facility, automatically a first digital orthopedic partial model of the orthopedic device to be manufactured is created based on the 3D body part model, and a second digital orthopedic partial model of the orthopedic device to be manufactured is created based on the generated digital component interface (25), wherein the digital orthopedic model of the orthopedic device to be manufactured is created in dependence on the first digital orthopedic model and the second digital orthopedic model.

7. The method as claimed in claim 6, wherein the second digital orthopedic model of the orthopedic device to be manufactured is created in dependence on the previously created first digital orthopedic model.

8. The method as claimed in claim 1 wherein, for each digital functional component model of an orthopedic functional component, at least one of dimensions of the component, an installation space of the component, a movement space of the component, stability properties, accesses for the installation and/or removal, tool attachments, supply lines, disposal lines, tolerable torques, occurring torques, possible functional component combinations, and thermal properties, are stored as a component property.

9. The method as claimed in claim 1 further comprising providing for visualizing one or more component properties on a playback unit of the data processing facility with or without the digital orthopedic model or a partial model thereof.

10. The method as claimed in claim 1 further comprising, in dependence on at least one component property of at least one selected functional component (26, 27), checking with the data processing facility whether a combination of the selected functional component and the provided 3D body part model, an orthopedic intended shape derived therefrom, and/or digital orthopedic model or partial model is producible and/or functional.

11. The method as claimed in claim 1 further comprising simulating by the dataprocessing facility, in dependence on at least one component property of at least one selected functional component, at least one movement and/or load of the orthopedic device to be produced and/or the selected functional component.

12. The method as claimed in claim 1 further comprising creating a digital surface model of the orthopedic device to be manufactured based on the 3D body part model and a border of the orthopedic device specified on the 3D body part model by the data processing facility, wherein the digital surface model forms an inside of the orthopedic device and wherein the digital orthopedic model of the orthopedic device to be manufactured is automatically created based on the digital surface model and a specified material thickness of the orthopedic device to be manufactured by the data processing facility.

13. The method as claimed in claim 1 wherein the orthopedic device producible using the created manufacturing data is an orthosis a prosthesis, or an exoskeleton.

14. A computer program having computer executable program code in a non-transient storage medium configured for carrying out a method as claimed in claim 1 when the computer program is executed on a data processing facility.

15. A method for manufacturing an orthopedic device, comprising: creating manufacturing data for the orthopedic device using the method as claimed in claim 1, supplying the manufacturing data to an automated manufacturing facility, wherein the automated manufacturing facility produces the orthopedic device using the created manufacturing data in an automated manufacturing method.

16. The method as claimed in claim 15, wherein the orthopedic device produced by the automated manufacturing method of the automated manufacturing facility, is produced in dependence on the supplied manufacturing data.

17. The method as claimed in claim 15 further comprising fastening at least one functional component on a receptacle of a component interface of the orthopedic device.

18. The method of claim 13 wherein the orthosis is selected from the group consisting of a foot orthosis, a hand orthosis, a knee orthosis, a torso orthosis, and a head orthosis.

Description

[0043] The invention will be explained in more detail by way of example on the basis of the appended figures. In the figures:

[0044] FIG. 1 shows a schematic representation of the method sequence according to the invention;

[0045] FIG. 2 shows a representation of a 3D body part model;

[0046] FIG. 3 shows a representation of an orthopedic 3D model;

[0047] FIG. 4 shows a representation of a cosmetic prosthesis during use;

[0048] FIG. 5 shows a representation of the integration of a first functional element;

[0049] FIG. 6 shows a representation of an interior of a cosmetic prosthesis;

[0050] FIG. 7 shows a representation of an integration of a second functional element.

[0051] FIG. 1 shows a schematic representation of the method sequence according to the invention, which begins with the provision of a 3D body part model 20 in the form of a digital intended shape 10. The 3D body part model 20 is a three-dimensional depiction of the relevant body part of the handicapped person. In the exemplary embodiment of FIG. 1, the digital intended shape 10 is an amputation stump of an amputated leg, for which a prosthesis is to be manufactured.

[0052] In the ideal case, the digital intended shape already has a shape and geometry, using which the medical indication of the handicapped person is to be treated as a measure. The digital intended shape accordingly has a shape and geometry which then results in a corresponding shape and geometry of the orthosis, using which the medical indication of the handicapped person may be treated and therefore represents the suitable treatment measures. Alternatively, the digital intended shape has a shape adapted to the individual anatomy of the handicapped person, which then results in a corresponding shape and geometry of the orthosis or prosthesis, using which this is matched particularly well to the shape of the body part and therefore results in increased wearing comfort. In particular in the case of prosthesis sockets, it is regularly advantageous to modify the 3D body part model and thus create an intended shape which takes into consideration the distribution of soft tissue, muscles, and bones.

[0053] The digital intended shape 10 having the 3D body part model 20 is now provided to a data processing facility 30, which has a computing unit 31 and a data memory 32. Computing unit and data memory can also be cloud-based solutions here. A plurality of digital functional component models are provided in the data memory 32, which are each integratable into the orthopedic device to be produced and create or provide a special additional function for the orthopedic device.

[0054] In the first step, the computing unit 31 in the exemplary embodiment of FIG. 1 is designed so that, based on the 3D body part model 20 or the digital intended shape 10, it carries out an analysis to thus create a first digital orthopedic model of the orthopedic device to be manufactured.

[0055] A technician 60 can influence the first partial model here. The technician 60 furthermore has the option of selecting one or more orthopedic functional components which are to be integrated into the orthopedic device to be produced. Based on the selection of the technician 60, the digital functional component models are then retrieved from the data memory 32, including the component properties stored for each digital functional component model.

[0056] In the next step, the computing unit 31 in the exemplary embodiment of FIG. 1 is designed so that based on the component properties of at least one selected digital functional component model of an orthopedic functional component, a digital component interface is generated, from which a second digital orthopedic partial model is then created. The digital component interface includes a receptacle here, which is adapted individually to the selected functional component based on the component properties and the digital functional component model so that the functional component may be integrated without problems into the digital component interface.

[0057] In the area of the receptacle, the digital component interface is adapted here to the selected functional component in accordance with the component properties in order to be able to receive the functional component later without problems.

[0058] A digital orthopedic model of the orthopedic device is now created by means of the computing unit 31 from the first digital orthopedic partial model and the second digital orthopedic partial model in that the two partial models are combined to form a joint overall model. The digital component interface is adapted here in the area in which the second partial model is fused with the first partial model, preferably so that the second partial model essentially corresponds to the first partial model in this area.

[0059] After the creation of the digital orthopedic model, corresponding manufacturing data are then generated which are then transferred to an automated manufacturing facility 50. The manufacturing data 40 can in the simplest case involve the created digital model, which is then analyzed by the automated manufacturing facility 50 to activate the facility, in order to generate the corresponding control signals for activating the automated manufacturing facility 50. However, it is also conceivable that the manufacturing data 40 already contain those control signals which are used to activate the automated manufacturing facility 50. This is ultimately dependent on the specific application and the type of the automated manufacturing facility 50 or the automated manufacturing method executed by the manufacturing facility 50.

[0060] In the exemplary embodiment of FIG. 1, the automated manufacturing facility 50 is a 3D printing facility, using which the prosthesis 100 can be automatically produced based on the digital model in an additive or generative manufacturing method. After the production of the prosthesis 100, the receptacles of the respective functional component provided in the component interface can then be physically inserted into the prosthesis 100. The prosthesis 100 can in this case, for example, be a prosthesis socket, on which additional prosthesis elements still have to be arranged.

[0061] The data processing facility 30 is additionally configured to allow a manual intervention by a technician 60, in order to thus create the option of manually manipulating the model and thus the orthopedic device to be produced. In this way, special wishes can be taken into consideration, which are not producible in an automated manner.

[0062] FIG. 2 shows an amputation stump 200 of an amputated leg, on which a prosthesis is to be arranged. The amputation stump 200 shown in FIG. 2 is a 3D body part model 20 here, which is the foundation for the creation of the prosthesis socket. The 3D body part model 20 was already supplemented by a technician here in such a way that borders 21 are provided, which represent the upper terminus of the prosthesis socket.

[0063] FIG. 3 shows the finished digital orthopedic model 22, as it is arranged on the 3D body part model 20. The digital model 22 includes a first digital partial model 23 and a second digital partial model 24 here, which are fused to form a common digital model 22. The second digital partial model 24 forms the digital component interface using which functional components 26, 27 are to be integrated into the orthopedic device as a whole.

[0064] This digital model 22 can now be used as the foundation for generating digital manufacturing data, in order to thus have an orthopedic device then produced on this basis, which can then be inserted later into the provided receptacles corresponding to the functional component.

[0065] FIG. 4 shows a cosmetic prosthesis 300 as an orthopedic device, wherein the cosmetic prosthesis 300 is to be arranged on a mechatronic knee joint 100 as a functional component. The functional component permits here, for example, controlled damping of the knee movement. Cosmetic prosthesis 300 and functional component 100 together form the prosthetic knee. A prosthetic foot is arranged distally on the prosthetic knee as a further functional component. The cosmetic prosthesis 300 can also provide an interface for this further functional component. The cosmetic prosthesis 300 is used here to improve the appearance of the prosthesis 100 and in particular to adapt the appearance to a contralateral body part which is still present, here a foot with a leg. Furthermore, the cosmetic prosthesis provides a protective effect for the functional components.

[0066] As shown in FIG. 5, further functional components 310 can also be integrated into such a cosmetic prosthesis 300, in order to further improve the function of the cosmetic prosthesis 300. In the exemplary embodiment of FIG. 5, a functional component 310 in the form of a soft knee is inserted here into the cosmetic prosthesis 300, in order not to damage the cosmetic prosthesis 300 when supporting or when kneeling down. The cosmetic prosthesis 300 includes an interface 320 for this purpose, in which the functional component 310 is inserted. In the exemplary embodiment of FIG. 5, the functional component 310 is inserted and held in a locking manner for this purpose.

[0067] During the generation of the digital component interface, upon selection of the functional component 310 shown in FIG. 5, a corresponding locking receptacle is to be provided in which the functional component 310 can be locked.

[0068] FIG. 6 shows a representation of a cosmetic prosthesis 300 known from FIGS. 4 and 5 with an inside view. A second component interface 330 is provided here in the interior of the cosmetic prosthesis 300, which forms a receptacle for arranging an orthopedic functional component in the form of a prosthesis. Due to the closing of the cosmetic prosthesis 300, this second interface 320 presses as elastic elements against the surrounding prosthesis (not shown), so that the cosmetic prosthesis 300 is thus mounted.

[0069] FIG. 7 shows a cosmetic prosthesis 300 in a further embodiment, in which a further, third functional component 340 is inserted or insertable. The functional component 340 shown in FIG. 7 is a cover, using which a functional unit located behind it and provided in the covered prosthesis is to be protected.

[0070] An opening is provided here in the cosmetic prosthesis 300, into which magnets are introduced in the border area, which form a third interface 350 together with the opening, in order to thus be able to accommodate the third functional component 340 (cover). Magnets are also introduced here into the third functional component 340, which interact with the magnets in the cosmetic prosthesis 300 so that the third functional component 340 is held magnetically in the opening. The cover ensures the protection of the functional component here, but also enables rapid and easy access thereto. In the illustrated example, easy access to the charging terminal of the functional component is thus enabled.

[0071] Further aspects of the cosmetic, such as the honeycomb structure, can also be adapted to the need of the respective selected functional components. A structure having many large openings can be provided, for example, for hydraulic knee joints, in order to thus enable a sufficient removal of the heat arising during damping.

LIST OF REFERENCE NUMERALS

[0072] 10 digital intended shape [0073] 20 3D body part model [0074] 21 border [0075] 22 digital orthopedic model [0076] 23 first digital partial model [0077] 24 second digital partial model [0078] 25 digital component interface [0079] 26 functional component [0080] 27 functional component [0081] 30 data processing facility [0082] 31 computing unit [0083] 32 data memory [0084] 40 manufacturing data [0085] 50 manufacturing facility [0086] 100 prosthesis [0087] 200 amputation stump [0088] 300 cosmetic prosthesis [0089] 310 second functional component [0090] 320 first interface [0091] 330 second interface [0092] 340 third functional component [0093] 350 third interface