3D Imaging acquisition, modeling and prototyping for facial defects reconstruction

A novel approach that combines optical three-dimensional imaging, reverse engineering (RE) and rapid prototyping (RP) for mold production in the prosthetic reconstruction of facial prostheses is presented. A commercial laser-stripe digitizer is used to perform the multiview acquisition of the patient's face; the point clouds are aligned and merged in order to obtain a polygonal model, which is then edited to sculpture the virtual prothesis. Two physical models of both the deformed face and the 'repaired' face are obtained: they differ only in the defect zone. Depending on the material used for the actual prosthesis, the two prototypes can be used either to directly cast the final prosthesis or to fabricate the positive wax pattern. Two case studies are presented, referring to prostetic reconstructions of an eye and of a nose. The results demonstrate the advantages over conventional techniques as well as the improvements with respect to known automated manufacturing techniques in the mold construction. The proposed method results into decreased patient's disconfort, reduced dependence on the anaplasthologist skill, increased repeatability and efficiency of the whole process. © 2009 SPIE-IS&T.