1. Materials and Costs Accuracy Viable Options Creative Labs Webcam Live! Motion: $102 – Amazon.com Strait-Line X3 Laser Level: $25 – Home Depot Calibration Grid - Included with the DAVID software Housing Components (wood, brackets, paint, etc): $46 – Home Depot Personal Computer – supplied by doctor Total Spent to date - $172 + Labor Cameras in Stereo Pairs Algorithm difficult to automate NextEngine® Desktop 3D Scanner Too costly Flatbed Scanner Inaccurate DAVID software with Laser and Camera Meets initial criteria DAVID is a freeware software program that requires a PC, a laser-level, a web camera, a 90 o angle, a calibration grid, and a target object. The proper procedure is as follows: 1.Calibrate the camera 2.Place the target object 3.Scan the object 4.Render a 3-D image Functional Goals Easy to use in under 10 minutes Apparatus External Dimensions: < 3ft x 3ft x 3ft Overall Cost per unit: < $400 Technical Goals Image Resolution: < 5mm between points Accuracy: 95% of points within 2mm Design a 3-D imaging device with the following minimum criteria: $692,955$603,755$679,195$589,995$713,595$624,39589,1995 $599,877$522,312$586,117$508,552$620,517$542,95277,5654 $518,940$451,493$505,180$437,733$539,580$472,13367,4483 $448,560$389,910$434,800$376,150$469,200$410,55058,6502 $387,360$336,360$373,600$322,600$408,000$357,00051,0001 High End ($8)Low End ($7)High End ($8)Low End ($7) Unit Furnishing Option TWOUnit Furnishing Option ONE Adjusted Cost Savings Using Maximum Shipping Cost Savings ($8) Minimum Shipping Cost Savings ($7) Inbound Molds Year Cash Flows Proposed Orthotics Manufacturing Process Michael Galante 1 Edward Krei 2 Derrick Snyder 1 Kathryn Yates 2 Paul King 2, Ph.D, P.E., Matt Moore 3 1 Department of Computer/Electrical Engineering, Vanderbilt University, Nashville, TN | 2 Department of Biomedical Engineering, Vanderbilt University, Nashville, TN | 3 Project Sponsor – Sole Supports, Inc., Lyles, TN NextEngine® Project Overview Project Requirements Sole Supports, Inc. is an orthotic shoe insole and sandal manufacturing company based in Lyles, Tennessee. As an industry innovator in producing custom insoles, Sole Supports is currently supporting physicians across the United States and looking to expand internationally. Their current process can be seen in the Original Orthotics Manufacturing Process Diagram below. This method is expensive and inefficient. The extra cost is ultimately passed on to the customer and the inefficiency consumes valuable time and money from all. Sole Supports has requested the services of our team to create an improved process that will save space, time, and money. We have determined that the main inefficiencies are generated by the shipping from the physician to Sole Supports and the warehouse storage. Digitizing the process by utilizing a 3D imaging device will save on both the time and expense of shipping, and allow for incredibly more efficient storage of each foot image. Our mission objective is to design and implement a software program and apparatus that is easy to use, accurate, and cost effective. Original Orthotics Manufacturing Process DAVID 3-D Imaging Software 4 Economic Benefit References 4 - DAVID Laserscanner website http://www.cs.tu-bs.de/rob/david.html Phantom Accuracy Points Phantom Resolution Area Cost Savings Summary One method of output from DAVID is a text file of listed points. These points were plotted in Matlab and segmented into the regions of the phantom. By creating a least-squares best-fit plane and calculating the distances form data points in each step, the distance from the true value could be found. With the steps going from 1 to 4 as shallowest to deepest, our results are shown in the table below. This shows that greater than 95% of our data points were within 2mm of the actual value. Our other goal was to have a data points at least every 5mm. To confirm this, a region of poor coverage was chosen and a 10x10mm box was drawn. The number of data points in the 100mm2 region was found to be 64, much more than the required 9. # of pointsAverage (mm)St. dev (mm)Actual (mm) Step1269.220.8511.0 Step22519.851.1322.0 Step31733.501.1734.5 Step425246.520.7246.0 Based on the purported economic estimates in conjunction with the accuracy results, we recommend that Sole Supports, Inc. seriously consider implementing our design. In the long term it will save the company a substantial amount of money from reduced shipping costs. Moreover, the process meets all criteria put forward by Sole Supports, rendering it an effective means to acquire accurate and precise data to be used for creating insoles.