Abstract: A method for fabricating a custom cranial remodeling device for correction of cranial deformities in a subject is described. The method comprises generating a three-dimensional head data file for the subject; identifying predetermined reference points on the head; automatically selective utilizing the predetermined reference points to calculate contour lines on the head; automatically generating a modified head shape data file; juxtaposing the modified head shape with the head represented by the three-dimensional head data file having the contour lines thereon; utilizing the modified head shape data file to generate a shape for a desired custom cranial remodeling device, the shape having an interior surface to contact the head and an outer surface; projecting lines outward from the contour lines to the outer surface; and utilizing the projected lines to establish cranial remodeling device contour lines for the custom cranial remodeling device.

Abstract: Apparatus is provided for point of service manufacture of custom headwear for a subject. The apparatus comprises capture apparatus disposed at a physical location for capturing three dimensional digital data of the head of the subject and generating a three-dimensional digital data file representative of said head; an additive manufacture device located at the physical location; and a processor. The processor operates to process the three-dimensional digital data file to produce a device file comprising the shape for the custom headwear and to provide the device file to the additive manufacture device. The additive manufacture device operates to utilize the device file to manufacture the custom headwear at the physical location.

Abstract: Custom manufactured headwear for a subject's head is provided. The headwear comprises an inner layer shaped to contact the head of the subject at predetermined areas. The inner layer is deposited by an additive manufacturing device. The headwear further comprises an outer layer deposited by the additive manufacturing device. The inner layer and the outer layer are each formed by the additive manufacture device utilizing a device data file derived from a subject data file. The subject data file is representative of the shape of the head and the device data file determining the shape of the headwear.

Abstract: A custom cranial remodeling device to correct a deformed head of a subject comprises an inner layer shaped to contact the head of the subject at predetermined areas, the inner layer is deposited by an additive manufacturing device and an outer layer deposited by the additive manufacturing device. The inner layer and the outer layer are each formed by the additive manufacture device utilizing a device data file derived from a subject data file, the subject data file representative of the shape of the deformed head, the device data file determining the shape of the cranial remodeling device to correct the shape of the deformed head.

Abstract: A method for fabricating an article of headwear for a subject is provided. The method comprises: generating a three-dimensional digital data file for the subject at a clinic by capturing a three-dimensional data file representative of the head by utilizing apparatus located at the clinic operating to capture three-dimensional data representative of the head; utilizing a processor to process the three-dimensional digital data file to produce a device file comprising the shape for the article of headwear; and manufacturing the article of headwear at the clinic by utilizing an additive manufacture device located at the clinic to operate with the three-dimensional digital data file.

Abstract: A method for fabricating a custom cranial remodeling device comprises generating a three-dimensional digital data file for the subject at a clinic by capturing a three-dimensional data file representative of the head of the infant by utilizing apparatus operating to capture three-dimensional data representative of the head. The apparatus is located at the clinic. The method further comprises utilizing a processor to process the three-dimensional digital data file to produce a device file comprising the shape for the custom cranial remodeling device and manufacturing the custom cranial remodeling device at the clinic by utilizing an additive manufacture device located at the clinic to operate with the three-dimensional digital data file.

Abstract: A method for fabricating a custom headwear for a subject is described. The method comprises generating a three-dimensional head data file for the subject; identifying predetermined reference points on the head; automatically selective utilizing the predetermined reference points to calculate contour lines on the head; automatically generating a headwear data file; juxtaposing the headwear represented by the headwear data file with the head represented by the three-dimensional head data file having the contour lines thereon; utilizing the headwear data file to generate a shape for a desired headwear, the shape having an interior surface to contact the head and an outer surface; projecting lines outward from the contour lines to the outer surface; and utilizing the projected lines to establish headwear contour lines for the custom headwear.

Abstract: A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.

Abstract: A method for processing a three-dimensional image file captured directly from a live subject, the file including the cranium of the subject, comprises: providing a vertex point cloud for the three-dimensional image file; determining a median point for the vertex point cloud; determining a point on the cranium; and utilizing the median point and the cranium point to define a z-axis for the three-dimensional image file.

Abstract: A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.

Abstract: A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.

Abstract: A method for processing digital image representations representative of a subject head shape comprises: providing a database library of a first plurality of first digital image representations of subject head shapes captured directly from corresponding subjects, and a second plurality of second digital image representations of corresponding modified head shapes. The method includes proving a support vector machine and utilizing the database library plurality of said first and second digital image representation to train the support vector machine to operate on new digital image representations. The method further includes receiving a new digital image representation of a subject head shape captured directly from a new subject; and operating the support vector machine such that the support vector machine operates on the new first digital image representation to generate a corresponding new second digital image representation that replicates a corresponding modified head shape.

Abstract: A method for processing a three-dimensional image file captured directly from a live subject, the file including the cranium of the subject, comprises: providing a vertex point cloud for the three-dimensional image file; determining a median point for the vertex point cloud; determining a point on the cranium; and utilizing the median point and the cranium point to define a z-axis for the three-dimensional image file.

Abstract: A method for processing a digital mesh representing a three-dimensional subject is described. The method comprises utilizing smoothed splines to identify inflection points on the mesh for further processing.

Abstract: A method for manufacturing a custom cranial remodeling device of a type comprising plastic material is provided. The method includes the steps of: providing a first database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a first type; providing a second database of three-dimensional digital surface images of trim lines for cranial remodeling devices of a second type; providing a first program for creating trim lines for a cranial remodeling device of the first type, the first program utilizing the first database; providing a second program for creating trim lines for a cranial remodeling device of the second type, the second program utilizing the second database; generating a three-dimensional model of a desired head shape; forming the plastic material onto the model; and selecting one of the first or the second programs to generate trim lines for the cranial remodeling device.

Abstract: A method for processing a three-dimensional image file captured directly from a live subject, the file including the cranium of the subject, comprises: providing a vertex point cloud for the three-dimensional image file; determining a median point for the vertex point cloud; determining a point on the cranium; and utilizing the median point and the cranium point to define a z-axis for the three-dimensional image file.

Abstract: A method for processing a digital mesh representing a three-dimensional subject is described. The method comprises utilizing smoothed splines to identify inflection points on the mesh for further processing.

Abstract: A method for processing digital image representations representative of a subject head shape comprises: providing a database library of a first plurality of first digital image representations of subject head shapes captured directly from corresponding subjects, and a second plurality of second digital image representations of corresponding modified head shapes. The method includes proving a support vector machine and utilizing the database library plurality of said first and second digital image representation to train the support vector machine to operate on new digital image representations. The method further includes receiving a new digital image representation of a subject head shape captured directly from a new subject; and operating the support vector machine such that the support vector machine operates on the new first digital image representation to generate a corresponding new second digital image representation that replicates a corresponding modified head shape.

Abstract: A method and system for automatically producing data representative of a modified head shape from data representative of a deformed head is provided. The method includes a step of processing captured data for the deformed head utilizing Principal Component Analysis (PCA) to generate PCA data representative of the deformed head. The method also includes the steps of providing the PCA data as input to a neural network; and utilizing the neural network to process the PCA data to provide data representative of a corresponding modified head shape.

Abstract: A method and system for automatically producing data representative of a modified head shape from data representative of a deformed head is provided. The method includes a step of processing captured data for the deformed head utilizing Principal Component Analysis (PCA) to generate PCA data representative of the deformed head. The method also includes the steps of providing the PCA data as input to a neural network; and utilizing the neural network to process the PCA data to provide data representative of a corresponding modified head shape.