Total Contact, a pioneer in burn mask production, uses a much less painful,
more efficient production method called image science, or non-contact surface
scanning and stereolithography (SL) technology. A laser scanner captures a
burn patient's facial contours in less than 15 seconds, creating a highly
accurate positive mask form. The data gathered from the scan is processed and
formatted for SL, which is then used to create the form. After the form has
cured, a plastic material is stretched over the form, producing the final mask.
Latest Challenge: Creating A Quick, More Accurate Positive Form
Jennifer Whitestone, biomedical engineer and president of Total Contact, says
that she began experimenting with the development of burn masks while working
for Wright-Patterson Air Force Base in Dayton, Ohio. From the outset, she
produced positive forms using a prototyping resin. Once the resin was cured,
the forms had to be able to endure demanding pressures and temperatures while
undergoing modifications. The resin she initially used had several drawbacks.
"The resin was not robust enough," said Whitestone. "It was too brittle and
could not hold up during sanding and vacuum forming processes. It was
inappropriate for creating a precise form for the face mask."
The Solution:
Bastech, Inc., a rapid prototyping service bureau,
was enlisted by Whitestone to create burn mask positive forms for Wright
Patterson Air force Base. To produce the forms, Bastech chose a new resin, DSM
Somos 7100 series resins to other brands and found that DSM offered a superior
product," said Pete Eros, Bastech design engineer. "The 7100 series has
improved build tolerance and speed. As a result, we have been able to increase
our productivity by at least 20 percent over the competitors' product," said
Eros.
Results:
DSM Somos 7110, coupled with image science, allows strong,
highly accurate and malleable forms to be fabricated, resulting in a premium
mask. Recently, Whitestone witnessed firsthand how the combination of these
technologies accelerates and improves the burn mask production process.
A five-year-old child and his family flew from their Colorado home to the
Total Control headquarters in Ohio to have a burn mask developed. Prior to
their visit, physicians and occupational therapists developed two burn masks
using the conventional plaster method for the child, but encountered
unsatisfactory results. Image science enabled the child and his family to
return home with a complete, more accurately fitting mask less than 48 hours
later.
Since that time, reports Whitestone, the boy's family and friends have seen
noticeable improvements in the appearance of his face. "The child's soft
tissue is healing better due to the accuracy of the burn mask, creating a
smoother skin surface and causing less abnormal scarring," said Whitestone.
For more information about Total Contact, call 937-229-6621 or visit their web
site at www.totalcontact.com;
Bastech, Inc., call 937-890-9292.
For further information on DSM Somos:
Melisa Lasell <
Europe@dsmsomos.info>
DSM Somos External Affairs Europe
Via
della Stazione 7F
00042 Anzio (Roma), Italy
Tel. ++39.06.986.5179
Cell. ++39.339.526.3828
