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Virtual and Physical Prototyping


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New challenges for reverse engineering in facial treatments: How can the
new 3D non-invasive surface measures support diagnoses and cures?
Luigi Maria Galantuccia
a
Rapid Prototyping and Reverse Engineering Laboratory, Dipartimento di Ingegneria Meccanica e
Gestionale, Politecnico di Bari, Bari, Italy

Online publication date: 17 May 2010

To cite this Article Galantucci, Luigi Maria(2010) 'New challenges for reverse engineering in facial treatments: How can
the new 3D non-invasive surface measures support diagnoses and cures?', Virtual and Physical Prototyping, 5: 1, 3 — 12
To link to this Article: DOI: 10.1080/17452751003718652
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Virtual and Physical Prototyping, Vol. 5, No. 1, March 2010, 312

New challenges for reverse engineering in facial treatments:


How can the new 3D non-invasive surface measures support
diagnoses and cures?
Luigi Maria Galantucci

Rapid Prototyping and Reverse Engineering Laboratory, Dipartimento di Ingegneria Meccanica


e Gestionale, Politecnico di Bari, Bari, Italy

Reverse engineering can give new challenges for diagnosis and facial treatments, offering
3D measurements, impossible to obtain only few years ago, in terms of richness of
information, precision, accuracy and reliability. In this paper the main aspects and
methods for skull and facial scanning and measurement are analyzed, considering
volumetric methods (CT, MRI) and surface approaches (laser scanning, structured light
and photogrammetry). These latter are particularly interesting because they avoid
exposing the patient to ionising radiation and to any biological risk. The EU directives
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in fact require minimisation of radiographic exposure, that will be in the near future
justified only for real diseases, but not for aesthetic treatments and surgery,
orthodontics, and malocclusions. Photogrammetry is very promising for the digital
reconstruction of human faces; it seems to offer the best compromise with respect to
realistic and accurate reproduction, processing time, simplicity and cost of equipment.
New software platforms have been developed to integrate the information acquired
using different tools: photogrammetry, CT/Cone beam computerized tomography
(CBCT), laser scans of dental cast study models. In this way a powerful multi-user
database system can be realised to track the patient’s imaging history throughout the
treatment cycle and to forecast the growth and the results of the treatments.

1. Introduction or acquired deformities, plan and evaluate interventions for


Three-dimensional measurements for anthropometric and surgery, study normal and pathological growth and to
aesthetic purposes have existed over the centuries, being verify the results of treatments.
used by artists and researchers who proposed methods A proper diagnosis is fundamental for any facial
useful for the definition and representation of human facial treatment (plastic and maxillofacial surgery, orthodontics)
features. A fundamental contribution to the scientific and researchers tried to find out much more about
approach and method was offered in the sixteenth century ‘evidence-based treatment’, following the implicit assump-
by Albrecht Dürer ‘Painter Surveyor and Clear’ in the tion that ‘the better the available evidence, the better the
Treaty ‘The symmetry of human bodies’: in the second book clinical judgments will be, and that the better the clinical
in particular Dürer exposed very accurately a mathematical judgments, the better the treatment outcomes will be. The
method for the geometric representation and construction target of each one of these concepts is the complex,
of three-dimensional human heads with double orthogonal multidimensional, and highly integrated approach toward
projections, defining 40 landmark points from which it was the patient’ (Baumrind 2006).
possible to obtain accurate reports of distances, angles and Normally the density of information in the intact patient is
proportions for the representation over 20 types of human transformed into a series of ‘physical records’, which
face (Figure 1) (Pezza 2007). experienced doctors consider necessary for the development
Anthropometrics is an objective tool for assessing facial of a comprehensive diagnosis and treatment plan, and these
form and detecting changes over time, to diagnose genetic include X-rays, cephalograms, photographs and plaster casts.

Virtual and Physical Prototyping


ISSN 1745-2759 print/ISSN 1745-2767 online # 2010 Taylor & Francis
http://www.tandf.co.uk/journals
DOI: 10.1080/17452751003718652
4 L.M. Galantucci

Figure 1. Albrecht Dürer: construction of the head of a man and method of double or orthogonal projection (Monge
method) (Pezza 2007).

Moreover, many clinicians believe that the generally high In recent decades, thanks to the availability of new
success rate of treatment is less based on good treatment systems for detection and measurement, anthropometric
planning than on the high level of clinical judgment and studies were carried out that considered three-dimensional
technical skill of an experienced doctor. surfaces (Jones et al. 1997), deepening the analysis of
In a few words, good treatment outcomes are strictly geometry and 3D morphologies of the major external
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achieved with the experience-driven ability of clinicians to tissues of the human body.
make ‘in-course corrections’ during treatment. To better Three-dimensional imaging is an innovative approach in
understand how clinicians make in-course adjustments the field of medical disciplines, particularly dental, which is
during treatment, it is necessary to develop rigorous becoming established both worldwide in clinical and
quantitative and non-invasive methods to improve encoding research fields (Sforza 2006).
and subsequent analysis of the visit-by-visit records of cure The algorithms of image processing applied to the facial
progress (Baumrind 2006). images can develop and improve anthropometric applica-
Radiological analysis is part of the gold standard for the tions, reducing the time needed for examination; they
diagnosis in fields such as orthodontics. However, it is improve the reliability of measurements, allowing detection
important to consider that X-rays are an invasive of clinically important distances and angles, and make
diagnostic tool. Directive 97/43/EURATOM says that the analysis and comparison of the form easier. Thanks to
radiographic exposure is justified only when patient the advantages of imaging technology, the use of surface
management depends on the information obtained from anthropometrics was extended to the full face, although not
the radiograph. The optimal testing of a diagnostic record for routine procedures (Douglas 2004). Essential practical
is to evaluate its consistency and validity. It is important to implementation for 3D anthropometrics is the ‘reverse
consider that problems such as aesthetic treatments, engineering’ (RE) technique, a technique which allows the
surgery, orthodontics and malocclusions, cannot be always reconstruction of a mathematical computer-aided design
considered as diseases: often they are not a biological (CAD) model of an existing object. In particular, it is able to
abnormal state. Thus assessment of the validity of a obtain information on 3D facial features of a person and
diagnostic record is not possible in the absence of the then to three-dimensionally reconstruct a model of the
true state of disease. Therefore, in studies where validity human face.
cannot be evaluated, comparison of consistency between
diagnostic records is a valid alternative. For example, in the
study by Nijkamp et al. (2008) no difference was found
between consistencies of orthodontic treatment planning 2. 3D Measurement of solids
with or without encephalograms obtained using X-rays. In There are several methods for acquiring data from a three-
other words, the effectiveness of cephalometrics for plan- dimensional object. They use different mechanisms or
ning orthodontic therapy is not proven; moreover, expo- phenomena to interact with the surface, or with the volume
sure to ionising diagnostic radiation is hazardous and has of the object. Figure 2 shows a classification of such
biological risks (Nijkamp et al. 2008). methods (Varady et al. 1997).
Virtual and Physical Prototyping 5

small elements, having triangular geometry, arranged in


space in order to accurately reproduce the body or the face
(meshed model in STL format). Within the non-contact
methods, we can further make the following classification:

. Methods based on transmission,


. Methods based on reflection.

2.1.1 Methods based on transmission: CT acquisition


The main advantages of the methods based on transmission
of energy are the ability to detect the internal cavity of an
object, not visible from the external, and the almost total
insensitivity of the system to changes in the characteristics
of the surface reflectivity of the object (Jones et al. 1997).
Among the methods based on transmission, computed
tomography (CT; or computed axial tomography (CAT),
helical CT, cone beam (CT)) is an important example of this
method for RE. CT uses X-rays with high energy, and the
system measures the amount of radiation that passes
through in different directions. The result is a mathematical
description of high-resolution surface and volume (with
volume elements called voxels).
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The reconstruction can be performed starting from Dicom


format files obtained from CT scanning, used for subsequent
Figure 2. Methods for measuring three-dimensional objects.
processing programs such as Mimics [www.materialise.com],
Maxilim [www.medicim.com], Amira [Enciso et al.], Dol-
For applications in medicine, non-contact methods are
phin 3D [http://www.dolphinimaging.com/3d.html], or free-
particularly interesting, because any pressure of the touch
ware or open source as Inversalius [http://en.wikipedia.
probe on soft tissue will influence the precision of the
org/wiki/InVesalius] and 3D Slicer [http://www.slicer.org/].
measurement of the body surfaces of the patient.
These programs use interactive displays to obtain three-
The information that can be obtained from the shape of
dimensional representations of objects. They also specialise
the human body, especially in facial metrology, has a large
in segmentation and image processing in shades of gray to
number of applications in medicine (Galantucci et al. 2002,
produce the STL format files, which are necessary for the
Naftel et al. 2002), but also for computer animation
reconstruction of the physical object using rapid prototyping
(Marschner et al. 2000, Sitnik et al. 2000), for teleconferen-
(Galantucci et al. 2006b).
cing and virtual reality (Shan et al. 2001), for forensic
Another key feature is the ability to see the masks in
applications (Introna et al. 2000) and for the realisation of
different shades of colour, incorporating the data input
products that take ergonomics into account (Wang et al.
tones of gray, or highlight the representation of tissues or
2003). In this paper only non-contact methods will be
organs with different colours. Figure 6 depicts a face and a
considered.
skull acquired on the three main orthogonal views. You can
see the yellow colour of bone tissue which has been a mask
for the subsequent operation of growing region, high-
2.1 Methods of non-contact measurement
lighting the jaw in different ways (colour fuchsia). This
These methods do not need touch between a mechanical representation is called tasselled, because the points corre-
contact probe and the object that must be measured: sponding to each voxel (in yellow and pink in Figure 3),
the interaction is implemented through electromagnetic have been joined by elements of triangular shape, and
fields, light or sound; the system obtains the information translated into STL format (Figure 4).
related to the investigation by the detection of the CT has been used to obtain the facial morphology in
transmitted or reflected waves from the body. The result is 3D; in addition to more traditional cephalograms and
a three-dimensional cloud of points representing the spatial photographs, they have the advantage of capturing, without
model of the body or face. Through the use of software additional computational effort, the information both of the
capable of processing the cloud of points, an area called a surface and the underlying hard tissues. But this method is
virtual mesh is created, consisting of a collection of many highly intrusive (biological damage from RX), expensive,
6 L.M. Galantucci

tomography has recently been developed and validated. This


innovative approach is a virtual bridge between the conven-
tional cephalometric and modern craniofacial imaging
techniques, and provides high quality, accurate and reliable
quantitative 3D data (Hammett et al. 2003).

2.1.2 Methods based on reflection


All 3D scanning systems based on mobile transmitters and
receivers fall into this category (Okada 2001). Among the
methods that exploit reflected energy, these can be distin-
guished as:

. optical methods,
. methods not based on the use of light sources.

Optical methods are probably the most popular systems for


the acquisition of forms of an object; they are characterised
by a speed of acquisition higher than the methods that
involve contact, and are certainly the most used for the
acquisition of surfaces as the easily deformable human skin.
The solutions offered by major manufacturers of equip-
ment for surface measures differ according to features such
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Figure 3. Skull acquired with CT (Mimics, [www.materialise. as: technology (laser scanning, projection of white light),
com]). building systems (fixed, CMM machines, robots, articulated
arm), or type measurement (scanning surface, scan profile)
and also requires the cooperation of the patient during long (D’Apuzzo 2006). The methods that detect the structures of
periods of scanning. CT also exposes the individual to 3D facial surfaces without the use of photos include laser
higher levels of ionizing radiation, compared with conven- scanning of surfaces, Moirè topography, photographs and
tional radiography. Even if cephalometric 2D images remain contour detection of reflective markers with infrared cameras.
the standard, computed tomographic reconstruction (MPR- The 3D optical techniques for the acquisition of faces can
CT) is now increasingly used for clinical purposes and jaw be divided into the following categories:
surgery. In recent years, image processing and 3D recon-
. 3D laser scanners,
struction of the landmarks have been widely applied to
. 3D imaging systems based on structured light projection,
digitised radiographs (Sforza 2006). A new method of
. instantaneous 3D imaging systems, based on photo-
cephalometric 3D based on spiral multi-slice computed
grammetry.

2.1.2.1. 3D Laser scanning system. The acquisition is done


by one or more laser beams captured by CCD cameras.
These methods are quite expensive, but also potentially very
accurate. In acquiring data from a non-static object, such as
a human face, there are significant limitations due to the
relatively low rate of acquisition. The subject can move
inadvertently during the acquisition, causing errors in the
final 3D model. 3D facial laser scanning systems (such as
the Minolta Vivid 910) were used in the dental field to
measure the morphology of the face and the landmark
points on the virtual model, in order to assess its reliability
in clinical perspective (Kau et al. 2005, Kovacs et al. 2006).
Two main types of laser scanner can be used for medical
purposes: automatic and manual. Both are based on a laser
Figure 4. Skull bones and skin segmentation (Maxilim, scan on the surface, The 3D scanner itself is realised by
[www.medicim.com]). combining the electronic control unit with a laser and one
Virtual and Physical Prototyping 7

Figure 7. Point cloud of a dummy head obtained using a


laser scanner.
Figure 5. Automatic Konica Minolta Vivid 910i laser
scanner. method of acquisition that results in no real points) and
scanning imperfections such as uneven distribution of
or more digital cameras that acquire the images and can points, irregularities and errors. Figure 7 shows the cloud
capture data at speeds up to 20,000 points/s. of points on the laser scan head of the face of a dummy, and
In the automatic configuration (Figure 5) the laser beam Figure 8 shows the meshed surface for a real face.
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is automatically scanned, while in the manual one (much During acquisition with laser technology, the patient
slower) the laser head is mounted on an articulated arm to should be supported using special supports to prevent
allow additional degrees of freedom for rotation movement movement. These can appear in the cloud of points gained
(Figure 6). The arm can easily be handled manually, creating and subsequently a filtering operation is necessary to
the best conditions for access to the surface to be scanned remove the extra information. This support also makes
without requiring any other alignment (neither face nor impossible the acquisition of areas of the face under the
machine) to a system of reference or pre-positioning. The same support; thus, to acquire complete data, more facial
result of a 3D acquisition technique is always expressed in scans are needed, and many clouds of points should be
terms of point cloud, i.e. a set of points in space, as identified merged. The merging of several clouds of points usually
by the coordinates (x, y, z) in a Cartesian reference system. introduces an overlapping error that can affect the accuracy.
The acquisition gives a representation only of the surface of
the object, and does not detect all the areas not accessible to 2.1.2.2. 3D imaging systems based on structured light
the laser beam (interior parts, recesses). projection. These systems are profilometers based on phase
The clouds of points obtained must be treated with measurement [http://www.3d3solutions.com/] or on the
appropriate software tools to remove noise (related to the

Figure 8. Face mesh of a PhD student obtained using a


Figure 6. Laser scanning done with articulated arm. laser scanner.
8 L.M. Galantucci

Moirè fringes (Sitnik et al. 2003). They require the projection landmarks, requiring palpation. Some landmarks used in
of patterns on the face and acquisition of the images via CCD anthropometry can be successfully detected by algorithms
cameras that will be elaborated to determine the 3D for image processing, since they are located at the edge of
coordinates of the points. Data scanning with structured the curves and contours (Douglas 2004, Sforza 2006).
light on real people can create virtual models of human faces, In the case of living persons, photogrammetric acquisi-
such as those shown in the work of Čarnickỳ et al. (2006), in tion using a single camera is much more problematic than
which an Eyetronics non-contact optical system is used. that of a static object: if the photos are taken in successive
moments, every movement, even very small, can make the
2.1.2.3. Photogrammetric technique. The 3D information is 3-D reconstruction impossible. In this case, to avoid any
obtained through the acquisition and comparison of multi- possible movement of the head, you should use a craniostat,
ple images (Hammett et al. 2003, Čarnickỳ et al. 2006, a device designed to keep the head still during the
D’Apuzzo 2002). The techniques based on the acquiring photogrammetric acquisition (Galantucci et al. 2006a).
photos can be distinguished by the number and types of Recently some equipment based on multiple cameras
images used. appeared on the market; these are devoted to surface
These methods are particularly suited to the digitisation of anthropometric surveying, in particular of the human face
the human body due to the insensitivity to slight movements. (Figures 912 [www.3dmd.com/, www.canfieldsci.com/,
Photogrammetry determines the position, shape and size of www.inition.co.uk/, www.dolphinimaging.com/]).
objects from their photos (Ferrandes et al. 2004). The The 3dMD system uses six digital cameras, three on each
method allows to take measurements without contact, and side of the patient, rotated inward at an oblique angle. Images
is based on the principle of triangulation. The photos should are generated by simultaneous 3D acquisition of structure
be taken from at least two different positions; three-dimen- and texture, with a capture time of less than 2 ms, with an
sional coordinates of the points of interest are obtained accuracy within 1 mm, and a resolution between 1 and
through the intersection of ideal lines drawn from each of the 70 polygons per mm2. Relative percentage changes between
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cameras to the object. The use of high-resolution digital images pre and post are more important than actual
cameras allows immediate verification of the acquired measurements of each image. With the 3dMD it is possible
images and simplifies the process of orientation. to generate a colour histogram of the differences between the
In anthropometry superficial indirect methods, such as pre- and postoperative digital images, overlying one another
photogrammetry, have several advantages over direct meth- based on user-specified markers. So colour changes allow the
ods: absence of contact, and shorter time of interaction surgeon to visualise the surgical transformation of the
with the patient. Therefore they are less influenced by the patient. 3dMD advantages are: simplicity of use, avoiding
behaviour of the subject. They can also make some any need of markers, or computed tomography scans, or
measurements, such as of the eye, that are difficult to laser. This system could be used to generate a new cephalo-
obtain with direct methods without causing discomfort or metric analysis based on three dimensions (Samson 2004).
injury to the patient (Swennen et al. 2005). The major limitations of these optical systems are primar-
In stereophotogrammetry, in order to facilitate corre- ily the cost, sometimes they are difficult to transport, and often
spondence between stereo images and the reconstruction of it is difficult to identify the landmarks on the computerised
the face, a grid of light can be projected in a random or reconstruction of the facial surface (Sforza 2006).
structured form. D’Apuzzo, et al. (2003) reported preliminary results
Examination of the literature shows that photogram- obtained with a fully automated test system that detects
metric measurements have been performed on the face facial features by using multiple images acquired from
rather than on other parts of the body. They have been used
multiple cameras simultaneously.
to monitor facial shape and its changes over both short and
long periods of time, during growth and during therapy.
The potential of photogrammetry as a means of recording
the face and its details, was seen before digital technology
3. Photogrammetry and laser scanning: a comparison
emerged, its primary advantage in medical applications due
to the fact that it is based on images: the lack of intrusion It is interesting to compare optical techniques, and particu-
prevents any inconvenience (discomfort), either physical or larly laser scanning and close range digital stereophotogram-
mental, to patients (Mitchell et al. 2002). metry. For laser scanning, the author used either a manual
In the literature there are many applications for the Kreon sensor (model KLS51) or an automatic scanning
detection of features from photos of faces, in particular to system (Konica Minolta Vivid 910i). When using a laser
the eyes, mouth, nose and lips. Photogrammetry is the most scanning system, in order to achieve good acquisition, the
appropriate measure of the landmarks related to soft tissue, person has to collaborate by staying motionless throughout the
while direct contact measures are preferable for the bone scanning (15 s). In fact, every small movement could produce
Virtual and Physical Prototyping 9

Figure 9. 3dMDfaceTM System [www.3dmd.com/].

errors in the resultant point cloud. A special device (cephalo- reconstruction of 3D shapes of human faces (Galantucci
stat) must be used to hold the head still during 3D acquisition. et al. 2009).
The equipment developed for the photogrammetric ac- Photogrammetry seems to offer absolutely the best
quisition (Galantucci et al. 2009) is simple and low cost: compromise with respect to all parameters used to evaluate
three or four digital cameras and photogrammetric software the systems of digitisation of human faces: realistic and
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are enough to obtain the 3D information (see Figure 13). accurate (Galantucci et al. 2006c) reproduction of the shape
With the photogrammetric technique data processing is obtained, processing time of the model, simplicity and low
slower, but the information acquisition, that is the time cost of non-invasive equipment.
spent to take the photographs, is very fast (1/5000 s, flash
time). Moreover, although less information about facial
shape is obtained using photogrammetry (less points), the
4. Perspectives
points whose 3D information are acquired are equally
spaced and cover the entire face and, after estimation of New software platforms are currently being developed
their spatial localisation, need no further processing. following an innovative approach to building healthcare-
Previous studies have indeed shown that the photo- focused 3D imaging application software tools. They
grammetric method is very promising for the digital provide users with a rich, easy-to-use, 3D patient treatment

Figure 10. OMNIATM [www.canfieldsci.com/].


10 L.M. Galantucci

Figure 11. Surface Imaging International Ltd. Vectra 3D Figure 13. Point cloud and mesh of the author obtained
Scanner [www.inition.co.uk/]. using photogrammetry.

visualisation platform built on an industrial strength tool that has been also provided [http://www.orthovisage.
communication platform. Exploiting the principle of Im- com/].
It is important to consider that while data on teeth are
age Fusion, they fuse the surfaces acquired by photo-
best captured from study casts, data on the osseous
grammetry with the CT/CBCT/digitised and dental cast
study models (Figure 14) to present information to assess supporting structures are best captured from 2D lateral
and frontal X-ray cephalograms or from CT; instead data
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patient treatment options where it is easy to support the


review of the patient condition, and then plan and simulate on the facial surface are best captured from facial photo-
possible treatment and surgery, monitor actual images of graphs. It seems to be that the fullest understanding of
progress and make evaluations of outcomes. In this way a growth and treatment processes could be obtained by
powerful multi-user database system can be realised to integrating data from these several sources into a contin-
track the patient’s imaging history throughout the treat- uous integrated system, to produce an integrated stereo
ment cycle for all team members to access at any point in model that begins to meet the needs of clinical orthodontists
time [http://www.3dmd.com/]. A new trend is to develop (Baumrind et al. 2003).
and to make available to the clinicians algorithms to The accuracy and reliability of measuring three-
forecast the growth and the results of the treatments. dimensional facial soft tissues were evaluated on groups
3D textured surfaces are produced to show how a patient of patients from Swennen for 3D CT and 3D stereophoto-
will be transformed after a specific treatment. Specific grammetry. 3D stereophotogrammetry has shown a great
options can be used if the patient is treated using surgical
implants. Movies can be also made so that 3D results can
be shown dynamically. This is a powerful and easy to use

Figure 14. Integration of different non-invasive surface


Figure 12. Dolphin Di3D high definition facial camera acquisitions (face done using photogrammetry, dental cast
system [www.dolphinimaging.com]. scanned using laser).
Virtual and Physical Prototyping 11

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