Case Studies in Scanning Humans to Create

Customized ProductsThomas Tong, 3D3 Solutions

Overview

• 3D3 Solutions has created 3D scanners that scan humans to create customized products

• Lessons learned for making 3D scanning usable by the general public

• 3 different cases - Feet, Faces and Joints

Goal

• Best practices for 3D scanning technology to solve human measurement problems

• Understand value proposition of moving 3d scanning from back-end systems

• Discuss risks and pitfalls

• Tackle production issues

Key Issues 1

• Scanning humans has different requirements than mechanical parts

• Movement• 3D scanning working

outside of controlled settings

• Used by untrained and non-technical operators

• Scanning speed and robustness

Key Issues 2

• The cost factor is challenging– Competition is traditional

tools– better, faster, or cheaper– Digital solutions has

different trade offs versus traditional tools

• Overcoming social fears

Methodology

• Custom build 3D scanners for each particular application

• Scanners prototyped and tested with end-users every step of the way

• Adapt available technologies, mix and match old and new techniques

• Modify the parameters of the problem

Case Study 1 – Feet

• Semi-custom to fully custom orthotics

• Scanning feet– Plaster cast and foam replacement

• Simple value proposition. Plaster and foam requires more time and physical handling costs– Digital scanning is simple, clean and fast

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Case Study 1 – Lessons Learned

• Scans asked to be highly reduced– High data sets = more storage, processing, and

transmission time• Less is more. The right measurements, not

more measurements• Scans data are used to look up into a model

library, additional data is not needed• Accuracy requirements are low. Ease of use

requirements are high• Time is money. Faster is better

Case Study 2 : Faces

• Faces– Medical

• Cosmetic surgery• Burn

– Visual effects• Digital Avatars• 3D Models

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Case Study 2: Lessons Learned

• There will be holes in a single scan – Solutions:

• Automatic - hole filling• Use replacement parts (No ears? No problem)• More cameras or scanners

• Glasses can be an issue• Hair in general does not scan that well

– Even if data is captured, a polygon mesh represents hair poorly

– In visual effects or games you would replace with a hair simulation

– For manufacturing, mesh may be okay

Case Study 2: Lessons Learned

• White light and laser safety– Rated to be safe– People are very skeptical, especially athletes

• Faces are the hardest thing to keep “still”• Different industries

– Visual effects, artists want to do lots of editing, can deal with lots of polygons

– For manufacturing, take the face or head scan and blend it in to a pre-existing model for less cleanup

Case Study 3 – Joints

• Bracing Products– Knees– Elbows– Ankles

• Data acquisition from multiple directions

Case Study 3 – Lessons Learned

• A fast 360 may requires multiple cameras– Systems that sweep around the joint will work– While humans are not rigid, general shape

remains unchanged

• Automated alignment can be challenging

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End User Issues• People don’t know what to

expect• There is significant reluctance

and fear– People worry about being

digitally “copied” especially women

– Social fears to the 3D scanning like early photographers

• Everyone moves all the time– Faster, higher cost, higher

quality scanners– Support the persons (Wall,

chairs)– Live with the noise

Lessons Learned

• Plan your scanner output to match required manufacturing input

• Fully automated solutions are difficult, but worth the effort

• Robustness is critical • 100% coverage near impossible• New methods will rarely be “cheaper” than

old methods. – The ability to digitally measure, analyze and

deliver data is valuable

Easy Wins

• 3D scanning is “cool”’

• Value proposition is straight forward– Existing solution is error prone, slow, difficult,

and requires shipping– Digital solution is fast, accurate and can be

digitally delivered

• Accuracy requirements are orders of magnitude lower than manufacturing

Future Steps

• Making simple and robust “1-click” scanning systems

• Look for end to end value, not just 3D scanning

• Develop digital measurement, analysis and information delivery platforms.

• Get more correct measurements more easily at a lower cost

Thank you!

Thomas Tong, 3D3 SolutionsEmail: thomastong@3d3solutions.com

Website: www.3d3solutions.com