3D scanning

The application of CAx tools in surgery is representing a breakthrough for clinical practice, both in terms of effectiveness and costs. Working directly on the patient's own diagnostic images, this approach provides powerful tools for pre-operative simulation, complex-surgery planning, quantitative evaluation of asymmetry or dysmorphism and for the design of the patient-specific instrumentation. To exploit its full potential, methodologies are being developed to automatize and simplify the existing tools and strategies, in order to make them available also to less experienced CAx users, or directly to the surgeons. With this aim, it is proposed a methodological procedure to automatically create a Statistical Shape Model of the cranial vault starting from a Training Set of pathologically unaffected adult crania. The Statistical Shape Model is useful as a template for a data-driven restoration of the physiological shape of the considered anatomy. The proposed procedure provides a reliable strategy for robust automatic detection of shape correspondence. Not requiring any user intervention, the number of samples in the Training Set can be increased at will to consequently increase the variability, and therefore the accuracy, of the resulting parametric model.

Keywords: CAx , Reverse engineering , Statistical Shape Model

In this study, we present a framework for seagrass habitat mapping in shallow (5-50 m) and very shallow water (0-5 m) by combining acoustic, optical data and Object-based Image classification. The combination of satellite multispectral images-acquired from2017 to 2019, together with Unmanned Aerial Vehicle (UAV) photomosaic maps, high-resolution multibeam bathymetry/backscatter and underwater photogrammetry data, provided insights on the short-term characterization and distribution of Posidonia oceanica (L.) Delile, 1813 meadows in the Calabrian Tyrrhenian Sea. We used a supervised Object-based Image Analysis (OBIA) processing and classification technique to create a high-resolution thematic distribution map of P. oceanica meadows from multibeam bathymetry, backscatter data, drone photogrammetry and multispectral images that can be used as a model for classification of marine and coastal areas. As a part of this work, within the SIC CARLIT project, a field application was carried out in a Site of Community Importance (SCI) on Cirella Island in Calabria (Italy); different multiscale mapping techniques have been performed and integrated: the optical and acoustic data were processed and classified by different OBIA algorithms, i.e., k-Nearest Neighbors' algorithm (k-NN), Random Tree algorithm (RT) and Decision Tree algorithm (DT). These acoustic and optical data combinations were shown to be a reliable tool to obtain high-resolution thematic maps for the preliminary characterization of seagrass habitats. These thematic maps can be used for time-lapse comparisons aimed to quantify changes in seabed coverage, such as those caused by anthropogenic impacts (e.g., trawl fishing activities and boat anchoring) to assess the blue carbon sinks and might be useful for future seagrass habitats conservation strategies.

Keywords: Habitat mapping , Mediterranean sea , Multibeam bathymetry , Object-based image analysis (OBIA) , Pléiades-HR satellite images , Seafloor mapping , Seagrass , Tyrrhenian sea , UAV

Introduction of collision models aided surgeons to plan their resection of the femoral and acetabular impinging deformities. Their application on the hip joint is particularly interesting in association with hip arthroscopy because with technique the vision is limited and identifying friction's zones is not easy. Although their large diffusion in the market, they still presents several limits. First, the 3D reconstruction has been used only in the preoperatory phase. Its use inside the operatory room is still not available. Furthermore the actual software lack of a pure automatized program to create the 3D model of the hip. Second, nowadays collision model's software separate and study only the bony part of the hip, erasing from the 3D reconstruction soft tissues. Third, the programs currently developed use statistical data as reference to 3d virtual models and the motion between the hip's bones. They base the motion analysis on the comparison between data extrapolated from the healthy population and data from the patient exam, consequently image processing may be inaccurate. Although according to our opinion collision model are useful even with their actual limits, in this chapter we describe the limits of the actual software and their potential development. © 2020 by Nova Science Publishers, Inc. All rights reserved.

In the last decades a variety of innovative craniofacial approaches has been adopted to entire skull base. The endonasal endoscopic route has emerged as a suitable methodology for several skull base lesions. An effective watertight closure is essential to isolate the intracranial cavity in order to restore the natural intra and extradural compartment division, necessary to prevent postoperative cerebrospinal fluid (CSF) leakage and complications such as meningitis, brain herniation, and tension pneumocephalus. The reconstruction can be performed using different materials, both autologous (autologous grafts) and non-autologous, individually or combined in a multilayer fashion. The harvesting a nasoseptal flap is one of the most effective techniques: it reinforces the skull base closure granting isolation of the surgical field. The current study was focused on the development of new advanced devices and techniques, aiding in reducing postoperative CSF leak, which is one of the most feared complication of this surgical procedure. Additive manufacturing allows to design devices with tailored structural and functional features, in order to satisfy all the requirements. On the other hand, the development of injectable semi-IPNs and composites clearly benefits from specific mechanical/rheological and injectability studies. Accordingly, starting from some basic concepts, innovative principles and strategies were also proposed towards the design of additively manufactured and injectable devices.

Keywords: additive manufacturing , CSF leakage , design of injectable systems , endoscopic endonasal surgery , reverse engineering , skull base reconstruction

Many women with early breast cancer undergo mastectomy as a consequence of an unfavorable tumor/breast ratio or because they prefer this option to breast conservation. As reported, breast reconstruction offers significant psychological advantages. Several techniques are currently available for the breast oncoplastic surgeon and offer interesting results in terms of aesthetic and patient-reported outcomes, using both breast implants and autologous tissues. On the other hand, advanced methodologies and technologies, such as reverse engineering and additive manufacturing, allow the development of customized porous scaffolds with tailored architectures, biological, mechanical and mass transport properties. Accordingly, the current research dealt with challenges, design methods and principles to develop 3D additively manufactured structures in breast reconstructive surgery.

Keywords: additive manufacturing , breast reconstructive surgery , design , fat grafting , reverse engineering , scaffold design

Nowadays, the quality assurance of aeronautical components is a very crucial issue. Diverse defects can be generated during composite material components manufacturing such as voids, delamination, cracks, etc. The identification of these defects requires the use of different types of inspection methods. In this paper, two diverse non-contact inspection techniques, i.e. a laser-based reverse engineering method and an ultrasonic testing procedure, are integrated to provide a complete quality assessment of carbon fibre reinforced polymer components for applications in the aeronautical field. A custom made software code was developed in order to create a user interface allowing for the visualization and analysis of the reverse engineering and ultrasonic information for the detection of geometrical and internal flaws of the component under inspection.

Keywords: Composite materials , Laser-based reverse engineering , Non-contact testing , Quality control , Ultrasonic non-destructive inspection

Fillets, rounds, chamfers and grooves are secondary features which are typically present in real manufactured mechanical components to satisfy some manufacturing and functional requirements. Despite the broad array of research conducted on feature recognition, the investigation of secondary features is a relatively new topic. All of the pertinent studies have been focusedonly on the recognition of secondary features from B-Rep models. The recognition and segmentation of secondary features from a discrete model is a non-trivial problem due to the same geometric descriptors that may be applied to both primary and secondary features. Moreover, although in real-world mechanical parts primary features are planes, cylinders or cones, the secondary features may be non-analytical and complex-shaped geometries. Further sources of uncertainty are the measurement errors and non-ideal geometries of the real objects to which the method is applied. To overcome these problems, a new and original method to segment secondary features of tessellated geometric models is proposed. The method is based on the analysis of geometric-differential properties and provides specific strategies that reduce its sensitivity to all of the above-mentioned uncertainties without affecting its selectivity. The proposed method, described in detail in this paper, is tested in some very critical cases, and the results are presented and discussed.

Keywords: 3D mesh segmentation , 3D scanning , Blending features , Features recognition , Fuzzy logic , STL

High accuracy digitalisation of geometric models, related to big size objects, usually is performed by means of multiple acquisitions from different scanning locations. It needs to correctly place the acquired point clouds in 3D digital environment. For this purpose, it is very important identifying the exact scanning location in order to correctly realign point clouds and automatically generate an accurate 3D CAD model. The present paper focuses on design and prototype of a mobile handling device for reverse engineering scanning systems, named Dedalo. It is able to locate itself using a sensor fusion method based on a Kalman Filter. The sensor equipment is composed by wheel encoders and an ultrasonic sensor for measuring the distance from a known reference. Although Dedalo is equipped with low-cost hardware, results have showed a location accuracy by 0,1% error/meter, better than each sensor accuracy.

Keywords: Kalman filter , Position measurement , Product design , Prototypes , Reverse Engineering , Sensor data fusion

Purpose: To examine the influence of different bulk and block composite and flowable and glass-ionomer material combinations in a multi-layer technique and in a unique technique, in deep Class I dental restorations. Methods: 3D CAD of the sound tooth were built-up from a CT scan dataset using reverse engineering techniques. Four restored tooth models with Class I cavity were virtually created from a CAD model of a sound tooth. 3D-finite element (FE) models were created and analyzed starting from CAD models. Model A with flowable resin composite restoring the lower layer and bulk-fill resin composite restoring the upper layer, model B with glass-ionomer cement (GIC) restoring the lower layer and bulk-fill resin composite restoring the upper layer, model C with block composite as the only restoring material and model D with bulk-fill resin composite as the only restoring material. Polymerization shrinkage was simulated with the thermal expansion approach. Physiologic masticatory loads were applied in combination with shrinkage effect. Nodal displacements on the lower surfaces of FE models were constrained in all directions. Static linear analyses were carried out. The maximum normal stress criterion was used to assess the influence of each factor. Results: Considering direct restoring techniques, models A, B and D exhibited a high stress gradient at the tooth/restorative material interface. Models A and D showed a similar stress trend along the cavity wall where a similar stress trend was recorded in the dentin and enamel. Model B showed a similar stress trend along enamel/restoration interface but a very low stress gradient along the dentin/restoration interface. Model C with a restoring block composite material showed a better response, with the lowest stress gradient at the dentin, filling block composite and enamel sides.

First aim of this paper is to describe a methodology developed to create virtual fragments of archeological archetypes in CAD (Computer Aided Design) environment. A simple Reverse Engineering (RE) technique was adopted to reconstruct the shape of vases allowing the archeologists, and so the CAD inexpert personnel, to use it. Moreover, another relevant aspect is the definition of a procedure to simulate shape errors on the virtual prototypes to make more realistic the results. The characteristics of the fragments to be reproduced were selected by means of Design of Experiment (DOE) techniques. So, an algorithm was implemented to simulate the shape error, related to the working operations, that represents the typical noise for the feature recognition of archeological findings. Furthermore, this algorithm can make more complex the hypotheses related to the Gaussian model of simulation of the error and can adapt the value of the shape error (i.e. increasing it) according to the data gathered in archaeological excavation. The case study was based on the definition of a catalogue of archetypes of the black Campanian vases studied and classified by the archeologist J.P. Morel. The procedure conceived was applied to five (among one hundred) vases of the virtual catalogue obtaining forty instances of fragments affected by errors and so creating virtual mock-ups of typical pieces which may be found in the archeological site considered for the case study.

Keywords: Archetype , Design of experiments , Geometric modeling , Profile reconstruction , Simulation of the shape and recognition errors

Purpose: Massive rotator cuff tears are common in the aging population. The incidence of failed rotator cuff repairs is still quite high, especially in the treatment of full-thickness tears or revision repairs. In this context, natural and synthetic meshes can be used as augmentation scaffolds or as devices to close the gap between a retracted tendon and the bone. The purpose of this work is to evaluate the ultimate tensile strength of different tendon-patch joints in order to consider their use in the treatment of massive cuff tears. Materials and methods: Porcine tendons and a synthetic low-density polypropylene mesh have been used. A preliminary study on the tensile strength of tendons and patches has been performed. Different patch-tendon joints have been studied by modifying the number and the layout of the sutures. For every joint, the tensile test, performed through an electromechanical machine, has been repeated at least twice to obtain reliable data. Results: Experimental tensile tests on tendons and patches have given good results with very low dispersion data. Mean values of the calculated ultimate tensile stresses are, respectively, about 34 MPa and 16 MPa for tendons and patches. As regards the sutures arrangement, the staggered layout gave, for all joints, a higher tensile strength than the regular (aligned) one. Different ultimate tensile stress values, depending on the sutures number and layout, have been calculated for the joints. Conclusion: Synthetic patches could be an interesting option to repair massive cuff tears and to improve, in a significant way, pain, range of motion and strength at time 0, so reducing the rehabilitation time. Obtained results demonstrated that joints with a suitable number and layout of sutures could ensure very good mechanical performances. The failure load of the tendon-patch joint, in fact, is higher than the working load on a healthy tendon.

Keywords: Experimental test , Reverse engineering , Rotator cuff tear , Synthetic patch , Tensile strength

The measurement of geometric deviations within large-size products is a challenging topic. One of the most applied technique compares the nominal product with the digitalization of real product obtained by a reverse engineering process. Digitalization of big geometric models is usually performed by means of multiple acquisitions from different scanning locations. Therefore, digitalization needs to correctly place the acquired point clouds in 3D digital environment. For this purpose, it is very important identifying the exact scanning location in order to correctly realign point clouds and generate an accurate 3D CAD model.The present paper faces the locating problem of a handling device for reverse engineering scanning systems. It proposes a locating method by using sensor data fusion based on Kalman filter, implemented in Matlab environment by using a low-cost equipment.

Keywords: Kalman filter , Position measurement , Product design , Prototypes , Reverse Engineering , Sensor data fusion

The use of fast and accurate scanning systems for human body digitization might pave the way towards the development of less invasive processes for medical manufacturing. In this work, an advanced measurement system for human body 3D reconstruction is used to design tailored assistive devices. The system is a photogrammetric 3D body scanner developed by the authors.

Keywords: 3D body measurements , assistive devices , medical manufacturing

Introduction and Objectives Fabrication processes for spinal orthoses require accurate three-dimensional (3D) models of the patients' trunk. Current methods for 3D reconstruction used in this field mainly include laser or structured light scanning; these methods are time expensive and invasive, especially for patients with partial disabilities. Therefore, a theoretically instant system for data acquisition of anatomical structure is highly desirable. The objective of this work is to show the feasibility of using digital photogrammetry for human body digitization to generate accurate 3D models of the patients' trunk for spinal orthoses fabrication. Materials and Methods Multiple synchronized two-dimensional images of the human torso are captured from different points of view using a photogrammetric scanner. A 3D model is generated using the state-of-the-art algorithms for point cloud and surface reconstruction. The digitized model is then used as input for the standard computer-aided design (CAD)/computer-aided manufacturing (CAM) process of fabrication. R4D from Rodin4D is used as prosthetics and orthotics CAD software. A robotic cell constituted by a six-axis KUKA KR 30-3 is used for milling a polyurethane foam. Vacuum forming is then adopted to generate the orthosis. Two spinal orthoses are fabricated using this approach and a classical one; then, they are evaluated using quantitative and qualitative metrics. Results The data acquisition using this approach lasts 50 milliseconds. The 3D reconstruction accuracy averages 0.21 ± 1.27 mm, which suits for the considered health care scenario. Results of the initial fitting of the orthoses fabricated with the presented method show better performances in terms of time (44%), product quality (35%), and patient experience (30%). Conclusions Digital photogrammetry can be used to enhance the data acquisition and data processing of anatomical surfaces for the CAD/CAM process of spinal orthoses. The data acquisition time, almost instant, allows an easy compliance of many patients. The data processing allows generating accurate models of the patient's body. The overall process generates orthoses with a better quality with respect to those manufactured using conventional procedures. ©

Keywords: CAD/CAM , fabrication techniques , photogrammetry , prosthetics and orthotics , spinal orthoses , three-dimensional reconstruction

Camera calibration plays a fundamental role for 3D computer vision since it is the first step to recover reliable metric information from 2D images. The calibration of a stereo-vision system is a two-step process: firstly, the calibration of the individual cameras must be carried out, then the two individual calibrations are combined to retrieve the relative placement between the two cameras, and to refine intrinsic and extrinsic parameters. The most commonly adopted calibration methodology uses multiple images of a physical checkerboard pattern. However, the process is time-consuming since the operator must move the calibration target into different positions, typically from 15 to 20. Moreover, the calibration of different optical setups requires the use of calibration boards, which differ for size and number of target points depending on the desired working volume. This paper proposes an innovative approach to the calibration, which is based on the use of a conventional computer screen to actively display the calibration checkerboard. The potential non-planarity of the screen is compensated by an iterative approach, which also estimate the actual screen shape during the calibration process. The use of an active display greatly enhances the flexibility of the stereo-camera calibration process since the same device can be used to calibrate different optical setups by simply varying number and size of the displayed squared patterns.

Keywords: Active display , Reverse Engineering , Stereo camera calibration , Structured light scanner

Aim. To evaluate the biomechanical effects of four different auxiliary-aligner combinations for the extrusion of a maxillary central incisor and to define the most effective design through finite element analysis (FEA). Materials and Methods. A full maxillary arch (14 teeth) was modelled by combining two different imaging techniques: cone beam computed tomography and surface-structured light scan. The appliance and auxiliary element geometries were created by exploiting computer-aided design (CAD) procedures. The reconstructed digital models were imported within the finite element solver (Ansys® 17). For the extrusion movement, the authors compared the aligner without an attachment with three auxiliary-aligner designs: a rectangular palatal attachment, a rectangular buccal attachment, and an ellipsoid buccal attachment. The resulting force-moment (MF) system delivered by the aligner to the target tooth and the tooth displacement were calculated for each scenario. Results. The maximum tooth displacement along the z-axis (0.07 mm) was obtained with the rectangular palatal attachment, while the minimum (0.02 mm) was obtained without any attachments. With the ellipsoid attachment, the highest undesired moments Mx and My were found. The rectangular palatal attachment showed the highest Fz (2.0 N) with the lowest undesired forces (Fx = 0.4 N; Fy = -0.2 N). Conclusions. FEA demonstrated that the rectangular palatal attachment can improve the effectiveness of the appliance for the extrusion of an upper central incisor.

Purpose: Pectus arcuatum is an anterior chest wall deformity that requires transverse wedge sternotomy. Determining and delivering the correct cutting angle are crucial for successful correction. This report describes the early clinical experience with a novel cutting template technology able to deliver the optimal cutting angle. Description: From patients' computed tomographic scans, the optimal cutting angle is obtained using computer-aided design. A template comprising slots tilted at the right cutting angle and a safety block to avoid damaging the posterior periosteum is printed through additive manufacturing. Evaluation: The template allows surgeons to perform a precise wedge sternotomy, safely sparing the posterior periosteum in all patients, without complications. Postoperative chest roentgenograms and clinical photographs demonstrate optimal sternal realignment and cosmetic outcome. In this report, the mean operative time was 110 minutes. All patients were successfully discharged, with a mean length of stay of 4 days. Conclusions: Transverse wedge sternotomy aided by a computer-aided design–devised cutting template may reduce the technical challenge of this procedure, thereby increasing its safety and reducing operative times and hospital stay. Further research on long-term patient outcomes is necessary.

Low-cost RGB-D cameras are increasingly being used in several research fields, including human–machine interaction, safety, robotics, biomedical engineering and even reverse engineering applications. Among the plethora of commercial devices, the Intel RealSense cameras have proven to be among the most suitable devices, providing a good compromise between cost, ease of use, compactness and precision. Released on the market in January 2018, the new Intel model RealSense D415 has a wide acquisition range (i.e., ~160–10,000 mm) and a narrow field of view to capture objects in rapid motion. Given the unexplored potential of this new device, especially when used as a 3D scanner, the present work aims to characterize and to provide metrological considerations for the RealSense D415. In particular, tests are carried out to assess the device performance in the near range (i.e., 100–1000 mm). Characterization is performed by integrating the guidelines of the existing standard (i.e., the German VDI/VDE 2634 Part 2) with a number of literature-based strategies. Performance analysis is finally compared against the latest close-range sensors, thus providing a useful guidance for researchers and practitioners aiming to use RGB-D cameras in reverse engineering applications.

Keywords: Active stereo , Depth camera , Device characterization , Performance comparison , RealSense D415 , Reverse engineering , VDI/VDE standard

3D models of submerged structures and underwater archaeological finds are widely used in various and different applications, such as monitoring, analysis, dissemination, and inspection. Underwater environments are characterised by poor visibility conditions and the presence of marine flora and fauna. Consequently, the adoption of passive optical techniques for the 3D reconstruction of underwater scenarios is a highly challenging task. This article presents a performance analysis conducted on a multi-view technique that is commonly used in air in order to highlight its limits in the underwater environment and then provide guidelines for the accurate modelling of a submerged site in poor visibility conditions. A performance analysis has been performed by comparing different image enhancement algorithms, and the results have been adopted to reconstruct an area of 40 m2 at a depth of about 5 m at the underwater archaeological site of Baiae (Italy).

Keywords: 3D reconstruction , Image enhancement , Underwater Cultural Heritage , Underwater imaging

Reverse Engineering (RE) may help tolerance inspection during production by digitalization of analyzed components and their comparison with design requirements. RE techniques are already applied for geometrical and tolerance shape control. Plastic injection molding is one of the fields where it may be applied, in particular for die set-up of multi-cavities, since no severe accuracy is required for the acquisition system. In this field, RE techniques integrated with Computer-Aided tools for tolerancing and inspection may contribute to the so-called “Smart Manufacturing”. Their integration with PLM and suppliers' incoming components may set the information necessary to evaluate each component and die. Intensive application of shape digitalization has to front several issues: accuracy of data acquisition hardware and software; automation of experimental and post-processing steps; update of industrial protocol and workers knowledge among others. Concerning post-processing automation, many advantages arise from computer vision, considering that it is based on the same concepts developed in a RE post-processing (detection, segmentation and classification). Recently, deep learning has been applied to classify point clouds, considering object and/or feature recognition. This can be made in two ways: with a 3D voxel grid, increasing regularity, before feeding data to a deep net architecture; or acting directly on point cloud. Literature data demonstrate high accuracy according to net training quality. In this paper, a preliminary study about CNN for 3D points segmentation is provided. Their characteristics have been compared to an automatic approach that has been already implemented by the authors in the past. VoxNet and PointNet architectures have been compared according to the specific task of feature recognition for tolerance inspection and some investigations on test cases are discussed to understand their performance.

Keywords: Deep learning , Injection molding , PointNet , Reverse engineering , Tolerance inspection