LAI PEI XIN KIB2001 U2103121/1

Department of Biomedical Engineering

Faculty of Engineering
Universiti Malaya

KIB2001 LAB 1
BioSculptor CAD/CAM Solution System

Name : LAI PEI XIN

Matrix number : U2103121/1
Date of experiment : 27/10/22 – 14/11/2022
Lecturer : IR. DR NASRUL ANUAR BIN ABD RAZAK
Lab assistant : MR. RAZALEE
Group :1
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1.0 ABSTRACT by Lee Wei Xuan

This experiment is conducted to design and analyse the upper limb orthosis (Wrist Hand Orthosis
– WHO) for rehabilitation purposes using BioSculptor CAD/CAM Solution System. The
measurement of circumference of the original upper limb is compared with the measurement
analysed by the system and the percentage difference is calculated. We also investigated the
machine error and changes occurring during the process of scanning, editing and printing.

2.0 INTRODUCTION by Lai Pei Xin

      A wrist hand orthosis(WHO) is used to support the wrist joint and limit the motion of the
hand during the recovery phase of certain medical conditions such as fracture and dislocation.
There are two different ways of fabricating a wrist hand orthosis (WHO).  First method is the
traditional fabrication method by manufacturing positive and negative WHO castings manually,
whereas the second method is using computer aided design and 3D printing to fabricate WHO.
We used the BioSculptor CAD/CAM solution system to design a Wrist Hand Orthosis (WHO) in
this experiment.

Picture 1: Wrist hand orthosis

    CAD/CAM refers to the integration of both Computer-aided design (CAD) and Computer-
aided manufacturing (CAM). In this experiment, CAD refers to the Bioshape software, while
CAM refers to the Biomill process using the milling machines which is controlled by the milling
machine operator. CAD, which is the Computer-aided design, is a very important process to
allow quicker iterations in the designing process and enable smooth transition in the CAM stage. 

     Throughout this experiment, we used a bioscanner to scan the arm of a student. The
biosculptor CAD/CAM solution system is one of the 3D imaging technologies in the healthcare
industry nowadays. The bioscanner laser line scanner is able to scan any part of the body
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segment of the patient's body and produce very detailed scans with fewer sweeps due to its dual
camera system. 

Picture 2: Bioscanner

     The Bioshape software is specifically designed by the Orthosis and Prosthesis experts for the
clinician and it has a number of modification tools such as image realignment, smoothing, filling,
sanding, cross-section pattern modification, tension factors and many more. The practitioner can
spin or rotate the model and move between two user defined views which is able to let the person
to visualize the model in a better way. This software is able to import and export the AAOP File
Interchange formats, and it is able to enter the patients’ measurements immediately and modify
them.

    The BioMill 4.5XF that was used in our experiment to produce the positive casting of Wrist
Hand Orthosis(WHO) utilizes the same standard CNC technology. The BioMill machine is very
accurate when cutting intricate shapes, sharp angles, trimlines and pediatric shapes at a high
speed. Its accuracy is up to 0.0111mm. The specified section of model also can be remill by
using this BioMill machine. CAMFoam which comes in various sizes and shapes are used in the
BioMilling process. CAMFoam has a lot of benefits as it has uniform cell structure, anti-static
formulation, it does not easily compress under vacuum, it works well with all carvers and so on.
All these properties of CAMFoam let the biomilling process go smoothly and a lot of industries
are using CAMFoam because it is low cost. 
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Picture 3: BioMill 4.5XF

Picture 4: CAMFoam

3.0 EXPERIMENT PROTOCOL by Asiyah Binti Mohamed Ashraf

3.1 Methodology

Software used: 
Bioshape Software and FastScan software.

Materials and apparatus:

BioSculptor’s Bioscanner, BioMill machine, CAMFoam, socks, cellotape and measuring tape.

Procedure:
Step 1: BioScanning

1. In this experiment, we use the left upper limb of the individual.

2. The cellotape is being placed on the distal part of the hand, wrist, medial part and
proximal part of the forearm. Then, the circumference of the distal part of the hand, wrist,
medial part and proximal part of the forearm are measured manually using measuring
tape. The distance between the proximal and distal part of the forearm is also measured.
3. The measurements are taken 5 times to get an average value.
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4. A sock is being used to cover the hand and forearm to ease the scanning process.
5. The individual is being seated and the forearm needs to be static throughout the scanning
process.
6. A miniature transmitter is placed on the proximal part of the forearm of the experimental
individual to detect the hand and accommodate for any movement.
7. The hand is scanned using BioSculptor’s Bioscanner to create a real-time scanned 3D
image in FastSCAN software.
8. Five scannings are taken and only one is chosen to be imported into Bioshape software
(from fsn format to obj format) for further analysis and modification.

Step 2: Bioshape

1. In the Bioshape Software, the image of the hand can be seen as 3D-shape.
2. Using the editing tool, a ‘clean’ button is pressed to remove unwanted noise that is being
scanned.
3. The elbow medial, elbow lateral, wrist anterior, wrist lateral, wrist medial, hand distal
and anterior part of the hand are labeled.
4. The 3D-shape  image is further smoothened for 3 times to get more accurate results.
5. The measurements of circumference are shown in the table and being compared with the
measurements taken manually.
6. The hand is being aligned to make sure all the points labeled are in the right position and
orientation.

  

Picture 5: 3D-shape

Step 3: Biomill

1. A CAMFoam is placed in the BioSculptor Mill and the wrist hand orthosis is printed.
2. The BioSculptor Mill rapidly cuts intricate shapes while preserving minute details of the
wrist hand orthosis.
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Picture 6: CAMFoam in BioSculptor Mill

Step 4: BioSculptor Analysis

1. The wrist hand orthosis sculpture is completed.

2. The wrist hand orthosis sculpture is being analyzed for the final stage. .

 Picture 7: Positive casting of Wrist Hand Orthosis

4.0 RESULT by Lee Wei Xuan

Table 1: Measurement of circumference distal part of the hand, wrist, medial part and
proximal part of the original forearm, 3D image in Bioshape Software and WHO sculpture
printed by Biomill.

Parts of Upper
Limb  Circumference (mm)
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WHO sculpture printed by

Original Upper 3D Image in Bioshape Biomill
Limb Software

Distal Hand 210 211.2 220

Wrist Hand 178 173.3 175

Medial Forearm 218 219.1 220

Proximal Forearm 260 260.9 265

Table 2:Percentage difference of each parts between original forearm, 3D image in

Bioshape Software and WHO sculpture printed by Biomill

Percentage Difference (%)

Parts of Upper
Limb
Between original limb Between 3D image and Between original limb and
and 3D image WHO sculpture WHO sculpture

0.57 4.08 4.65

Distal Hand
2.67 0.98 1.70
Wrist Hand
0.50 0.41 0.91
Medial Forearm
0.34 1.56 1.90
Proximal
Forearm

Calculation 

4.3 Calculation

Formula Percent Difference: 

LAI PEI XIN KIB2001 U2103121/1

Percentage difference between original limb and 3D image:

|210-211.2|(210+211.2)/2 100% =0.57%

|178-173.3|(178+173.3)/2 100% =2.67%
|218-219.1|(218+219.1)/2 100% =0.50%
|260-260.9|(260-260.9)/2 100% =0.34%  
   
 Average:     0.57%+2.67%+0.50%+0.34%4=1.02%

Percentage difference between 3D image and WHO sculpture::

|211.2-220|(211.2+220)/2 100% =4.08%

|173.3-175|(173.3+175)/2 100% =0.98%
|219.1-220|(219.1+220)/2 100% =0.41%
|260.9-265|(260.9-265)/2 100% =1.56%  
   
 Average:     4.08%+0.98%+0.41%+1.56%4=1.76%

Percentage difference between original limb and WHO sculpture:

|210-220|(210+220)/2 100% =4.65%

|178-175|(178+175)/2 100% =1.70%
|218-220|(218+220)/2 100% =0.91%
|260-265|(260-265)/2 100% =1.90%  
   
 Average:     4.65%+1.70%+0.91%+1.90%4=2.29%

DISCUSSION by Lai Pei Xin (individually)

CONCLUSION by Nur Sahira Binti Mohamad Nazri

 
To conclude, the main objectives of this experiment have been achieved successfully. In this
experiment, we have learned how to design and analyze an upper limb orthosis (Wrist Hand
Orthosis - WHO) for rehabilitation purposes using the BioSculptor CAD/CAM system. This
system involves 3 steps, the first step is bioscanning by using Bioscanner and FastScan software,
then modifying the scanned model by using BioShape apps, lastly is printing the model using
Biomill software. 
        
        Furthermore, we also have been introduced by a new Bioscanner, which is Spectra 3D
Prosthetics and Orthotics Scanner. The scanner is more advanced and has a lot of new features to
get more accurate circumference measurements. The scanning process of this advanced Spectra
3D scanner using CapSpectra software and Scanfit apps to design the orthosis. This simplifies
the process and allows users to present the results more accurately to the patient. 

     Next, we also can conclude that the body segments of each and every one of us is different
and unique, according to Drills and Contini theorem and the aim of the study is to develop
relationships between body parameters and how it will impact our daily life. We successfully
LAI PEI XIN KIB2001 U2103121/1

measured the body segments and study the science behind the values we received. These values
really help ourselves to learn more about ourselves and our bodies.

REFERENCE by Yunis Naidu A/L Govindarajaloo

https://www.researchgate.net/publication/273610396_Computer-
aided_design_to_support_fabrication_of_wrist_splints_using_3D_printing_A_feasibility_study 

https://biosculptor.com/bioscanner/

https://journals.sagepub.com/doi/abs/10.1177/1758998314544802 

https://www.oandpeast.com/services/3-d-imaging-technology 

https://en.wikipedia.org/wiki/CAD/CAM 

https://www.brbiomedical.com/cad-cam-po.php 

https://revelationmachinery.com/product/biosculptor-cnc-biomill-4-5-axis-milling-foam-
machine/