Made4Eyes B.V. (M4E) has been customizing eyewear since 2015 using 3D scan and 3D printing technology. M4E uses a Structure Sensor from Occipital to scan the spectacle wearer. At the beginning of 2019, M4E launched a new brand, custom-made glasses from Maat!, aimed at people who do not have a standard face shape. These are often people with a medical condition, such as Down syndrome, people with a craniofacial (skull) disorder or other conditions.
In the past few years, M4E has noticed the necessity to innovate in two areas to guarantee or improve the quality of the glasses. Some of the clients are (small) children and have a mental disability, which makes it difficult for them to sit still for 10 seconds, which is needed for a scan to be properly registered. Another problem that occurs is the ergonomic accuracy. The ends of the legs (ear tips) are often not well enough shaped for small children and people with a strongly deviating skull shape. In these cases, the frames offer too little support, causing the glasses to sag. Since the 3D-scan doesn’t reach the area behind the ear, this geometric information is missing. By researching the ergonomics of the skull in this target group and in particular the shape behind the ear, Maat! wants to obtain insight into the similarities and differences between the age groups and any common disorders. The shape of the nose and the weight of the glasses (as a result of increasing strength) will also determine the design of the spring tips.
Maat! is looking for a cheap and mobile 3D scanning technology that can create an accurate mesh in a fraction of a second and includes a photographic texture so that glasses can be alligned on the head in a 3D viewer software. Besides that, Maat! wants to gain insights in geometry behind the ear between different sub-groups and have a new methodology to customize ear tips.
Combining these two new technologies, Maat! Strives to get a 95% RFT (Right First Time) value.
In the project, 3D data was gathered by employing scanning technologies. The head scanner project involved evaluating the current 3D-head scanning method and subsequently developing a new scanner that fulfils the project's requirements. A photogrammetry-based system was chosen, where multiple images are stitched together to form the final scan. This involved the use of three Intel RealSense scanners housed in a 3D-printed enclosure, optimised for user comfort by allowing as much distance from the head as possible.
The development of new equipment was a significant part of the head scanner project. After thorough research, a scanner comprising three Intel RealSense scanners in a 3D-printed enclosure was constructed. The design and orientation of the scanner were tailored to the use case, emphasising ease and comfort for the client during the scanning process.
The ear tip project required careful selection of data from scanning devices and molds to capture the geometric details behind the ears of clients and volunteers. This process was guided by the project's objectives, focusing on obtaining accurate geometric information despite challenges such as extended lead times due to pandemic-related measures.
The analysis of 3D-scan data in both sub-projects involved comparing various designs to achieve the optimal shape and fit. In the ear tip project, statistical analyses of the 3D-scan data led to different designs for the ear tips of the temples. The comparison process was vital to refining the design to better match the individual shapes of clients' skulls, as illustrated by the modifications made to the temple tips for enhanced grip and comfort.
The culmination of the two sub-projects has significantly enhanced M4E's expertise in using 3D scanning technologies, yielding a wealth of knowledge and practical experience. The head scanner project succeeded in creating a functional device tailored for M4E's application, though it necessitates further refinements for optimal integration into their operations. Key improvements could focus on the scanner's housing and user interaction to alleviate feelings of intimidation or claustrophobia among some clients.
In contrast, the ear tip project introduced innovative approaches to design and fit, suggesting potential advancements through increased participant diversity and enhanced geometric differentiation. However, both projects encountered delays and complications, particularly due to COVID-19 related restrictions affecting research progress and client interactions. Despite these challenges, the projects demonstrated commendable creativity, especially in the initial stages of the ear tip project. Moving forward, incorporating a broader participant base and addressing the identified areas for improvement could further refine these technologies, contributing to M4E's competitive edge in the market. The knowledge gained not only advances M4E's operational capabilities but also contributes to the broader field of 3D scanning technology applications.
