3D Imaging Software Brad Boldizar, Aubrey McKelvey, and Mackenzie Thomas Advised by: Dr. Paul King Matt Moore

Flow Chart of the Sole Supports Current Manufacturing Process 2. Doctor sees patient in office 3. Doctor imprints patient’s foot into foam 1. Sole Supports sends foam blocks to participating doctors 4. Doctor sends imprinted foam blocks back to Sole Supports 5. Sole Supports checks for shipping damage Shipping ~160 pairs/day

Flow Chart of the Sole Supports Current Manufacturing Process 4. Doctor sends imprinted foam blocks back to Sole Supports 5. Sole Supports checks for shipping damage 6a. If foam is undamaged, Sole Supports makes the actual insole 6b. If foam is damaged, Sole Supports sends more foam to the doctor for re-imprinting 6c. Doctor calls patient back into office for re- imprinting Shipping

Flow Chart of the Sole Supports Current Manufacturing Process 6d. Doctor sends imprinted foam blocks back to Sole Supports Shipping 6a. If foam is undamaged, Sole Supports makes the actual insole 6b. If foam is damaged, Sole Supports sends more foam to the doctor for re-imprinting 6c. Doctor calls patient back into office for re- imprinting Shipping

Flow Chart of the Sole Supports Current Manufacturing Process 6d. Doctor sends imprinted foam blocks back to Sole Supports 7. Sole Supports sends the insoles to the doctor’s office 8a. Doctors fit the patient with the new custom insoles 8b. Sole Supports keeps plaster molds of patient’s feet for 6 months or more Shipping 6a. If foam is undamaged, Sole Supports makes the actual insole

Our Solution Solution  Supply doctor’s offices with scanner/camera apparatus so they can image to Sole Supports.  Sole Supports will use computer code to translate scanned image into 3D data points, which can be used to create the insole. Advantages:  Solves problem of foam blocks crumbling during shipping.  Sole Supports can check for improper casting almost immediately.  Over time, frees up storage space. Disadvantages:  Upfront cost.

Cost Analysis on Shipping Current Method:  Best Case Scenario: Shipping from Sole Supports to Doctor’s Office = 2 times Shipping from Doctor’s Office to Sole Supports = 1 time Total = 3 times * $8 = $24  Worst Case Scenario: Shipping from Sole Supports to Doctor’s Office = 3 times Shipping from Doctor’s Office to Sole Supports = 2 times Total = 5 times * $8 = $40 Proposed Method:  Best Case Scenario: Shipping from Sole Supports to Doctor’s Office = 2 times Shipping from Doctor’s Office to Sole Supports = 0 times Total = 2 times * $8 = $16  Worst Case Scenario: Shipping from Sole Supports to Doctor’s Office = 3 times Shipping from Doctor’s Office to Sole Supports = 0 times Total = 3 times * $8 = $24 Sole Supports can save $8-$16 per pair of insoles, and at 160 pairs/day, this amounts to about $463,680 per year saved on shipping, not to mention the time savings.

Cost Analysis on Store Room Current manufacture space: 10,000 sq ft Estimated gained space: 10,000 sq ft Estimated profit per sq ft: $400 Double profit

Cost Return With the $1200+ savings per day on shipping and estimated profit margin available by opening up the storage space to become extra manufacturing space, Sole Supports has the potential to make a quick turnaround on the startup costs. In terms of profit, this project won’t necessarily be a huge money-maker for the company. However, they will be able to gain back any upfront costs relatively quickly. They can also expand their “footprint,” so-to- speak, by being able to cater to more international doctor’s offices.

Our project flowchart scanner.txt file x y z … RHINO program (Sole Supports) 3D Milling Machine (Sole Supports) scanned foot impression (.bmp) Python Program Scale

Accuracy Needed According to preliminary testing of RHINO software with the 3D milling machine at Sole Supports, it has been determined that the system works well with an error of 2mm or less. The lower the intensity of the scanner light, the better the scanned picture will be. Change the level of light:  Resistor  Tinted Transparency Paper

Software The software environment has been re- engineered. LabView didn’t provide appropriate data manipulation tools. A new program was written in the Python programming language.

Software The program creates a simple, comma-delineated text file. It lists the X and Y coordinate, along with the light intensity at that exact pixel. The RHINO software that Sole Supports possesses can take this data and “loft” it (convert numerical data into a 3D point cloud model).

Software – Lofted Model

Scaling X and Y dimensions can be calibrated with a ruler on the scanning bed, and a frame can be set so the scaling will be permanent. The Z dimension is more complicated. A control distance (foam from scanning surface) will be set, then a ramp/slope can be scanned and the intensities can be compared with the distances. The results of these procedures could then be incorporated into the programming code.

Past Work Met with Sole Supports advisor to make sure our design meets their criteria. Created Python program to convert scanned image into (x, y, z) data points. Sent test data to Sole Supports for graphing in 3D via RHINO. Created prototype apparatus based on design criteria.

Current Work Refine scaling method so that (x, y, z) points can be used to mill out a real imprint. Determine accuracy from this milled foam impression. Create a real apparatus using prototype specifications.

Future Work Determine scaling and accuracy. Finish building apparatus. Write paper. Make final presentation.

Timeline March 31: Tweak scanner to give lower intensity. Work on scaling method. April 7: Turn prototype apparatus into first generation apparatus. Begin testing accuracy. April 14: Begin work on final paper and presentation. April 25: Design Day! Final Report and Presentation due.