KS1 Use Case - Custom Wrist Braces

February 13, 2017

Not interested in reading? Checkout the video here!

Here at Knockout we're constantly being pulled in multiple directions for different projects. Between educating people about the power of Mobile 3D Scanning, to being asked to partake in clients project, and working on our own projects, Knockout is constantly busy and pushing the 3D envelope. The KS1, Knockout's mobile 3D scanner, is at its core a tool. How you want to use it is entirely up to you, but there is absolutely no doubt that the functionality of the device opens up a whole new world for your workflow. We are constantly featuring how other people use the mobile 3D scanner, so we decided to share some of the projects we have going on here at Knockout HQ.So, let's get to it! This week we want to talk about the custom wrist guards we're developing. The great thing about the KS1 is that it's mobile! It's locational flexibility allows us to scan in different environments, scan organic and inorganic objects, and scan on the fly. We've developed an extensive database of scans just because the KS1 can be brought anywhere we go. As with most of our projects, this one starts off with using our mobile 3D scanner, the KS1. Because our proprietary software is incredibly accurate, we were confident that scans of Brooks and Jake's wrists' would be to scale and precise.

Brooks Myers, Knockouts CEO, scanning Jake Kuttothara, Knockouts COO, for his wrist brace.
‍Jake scanning Brooks for a wrist guard.

From there, we took our 3D files and manipulated them. We use a few 3D tools to manipulate our mobile 3D scans, but for this project we used Mesh Mixer. First things first, we cleaned up the scans and removed any material that wouldn't be necessary for making wrist guards. To make Brooks' wrist guard, in which the goal was to project his hands from falls off his skateboard, we cut out an area around his palm and wrist and extruded that form. Because Jake's brace fully surrounded his wrist, his extrusion process was a bit more difficult. First, we isolated the shape of the brace and then used an offset to give a small amount of room between himself and his brace. Next, we extruded the form to give it some rigidity.

‍Extrusion of Jake's wrist brace
‍Extrusion of Brooks' wrist guard

We used two different methods to give the brace and the guard their polygonal forms. For the guard, we used the adaptive/reduce brush to actually decimate the shape, thus exposing larger triangles in the design. For the guard, we also decimating the triangle count to expose a triangulated mesh. We then applied an edge pattern to the extruded mesh triangles, thus giving it its polygonal form.

‍Applying the edge pattern to our mesh.
‍Using the adaptive/reduce brush to expose the braces polygonal pattern.

From here, we took our manipulated 3D files to our trusty 3D printer, a Lulzbot Taz 5.  We used ABS for Brooks' wrist brace as ABS has more industrial applications. ABS has superior layer bondage to PLA and is therefore more impact resistant. This, combined with a 50% infill, led us to believe the guard would be able to survive a full on crash. For Jake's wrist brace, however, we used PLA. PLA is corn based, which felt important to us as it would be touching his skin for an extended period of time. We also used a 20% infill as we wanted the brace to be light, while still being able to withstand everyday usage.

‍Jake's wrist brace being printed out of PLA
‍Brooks' wrist guard being printed out of ABS

A bit of post print sanding and voila! Thanks to Knockout's scanner, the KS1, we now have fully customized wrist guards. Checkout our video documenting this process on our Facebook! Thanks for reading and come back next week for another post.