Custom prosthetic devices and methods of fabricating them using visible reverse imaging

Claim 2

A process for fabricating a custom prosthesis for use in lieu of one of a pair of natural body members of a subject, including: forming a negative cast mold of a portion of a body of a subject including at least an attachment site from which one of a pair of natural body members has been removed, and against which a prosthesis is to be attached in lieu of a removed one of the pair of natural body members; forming a positive impression of said negative cast mold, said positive impression including a replication of the attachment site; coating the positive impression with a curable material to form a first prosthesis wall; generating a visible reverse image of another, remaining one of the pair of natural body members; using the visible reverse image to form a positive body member mold simulating said visible reverse image; forming a negative cast mold of the positive body member mold to provide a negative body member mold; coating the negative body member mold with a curable material to form a second prosthesis wall; juxtaposing the first prosthesis wall and the second prosthesis wall such that the prosthesis walls contact one another and cooperate to enclose a chamber; and bonding the prosthesis walls to one another while they are so juxtaposed, to form an external prosthetic enclosure.

Claim 3

The process of claim 1 further including: after bonding said walls, injecting a filler medium into the chamber.

Claim 4

The process of claim 2 wherein: the filler medium comprises a silicone gel.

Claim 5

The process of claim 1 wherein: generating the visible reverse image comprises using a mirror to take a reverse image photograph of one of: the remaining natural body member, and a replica of the remaining natural body member.

Claim 6

The process of claim 4 wherein: the replica of the remaining natural body member comprises a portion of said positive impression.

Claim 7

The process of claim 1 wherein: generating the visible reverse image comprises measuring one of: the remaining natural body member, and a replica of the remaining natural body member.

Claim 8

The process of claim 6 wherein: said measuring is performed using a laser.

Claim 9

The process of claim 1 wherein: forming the positive body member mold comprises sculpting clay.

Claim 10

The process of claim 8 wherein: forming the negative body member mold comprises juxtaposing the positive body member mold and the positive impression against one another with a rearward portion of the positive body member mold against said replication of the attachment site; surrounding the juxtaposed positive body member mold and positive impression with a containment wall; and filling the space between the juxtaposed positive mold and positive impression and containment wall with a casting material.

Claim 11

The process of claim 1 wherein: bonding the first and second walls comprises curing the first and second walls simultaneously while they are so juxtaposed.

Claim 12

The process of claim 1 wherein: the bonding of the first and second walls seals the chamber.

Claim 13

A custom prosthesis formed according to the process of claim 1.

Claim 14

A custom prosthesis formed according to the process of claim 2.

Claim 15

The process of claim 1 further including: fabricating an inner wall of a curable material; with the first and second walls so juxtaposed, further juxtaposing the inner wall against the first wall and in the chamber; and bonding the inner wall to the first wall to form an air pocket within the chamber.

Claim 16

The process of claim 14 wherein: bonding of the inner wall and first wall seals the air pocket.

Claim 17

The process of claim 15 further including: injecting a filler medium into the chamber and outside of the air pocket.

Claim 18

A custom prosthesis formed according to the process of claim 14.

Claim 19

A custom prosthesis formed according to the process of claim 16.

Claim 20

A process for fabricating a custom prosthesis, including: forming a negative cast mold of a portion of a body of a subject including at least a prosthesis attachment site, by covering a desired portion of the body with a first layer of a paste material wherein the desired portion includes a substantially larger area than the area to be treated, and disposing upon the paste material at least one covering layer; forming a positive impression of said negative cast mold by applying at least a first coat of a paste material upon an inner surface of the negative cast mold, and removing the positive impression from the inner surface of the negative cast mold; generating a visible reverse image of a desired aspect of the body to be replicated, based on parameters measured from at least one member selected from the group consisting of an existing section of the body to be replicated and a reshaped surrogate of said section; simulating the visible reversed image to form a sculptured model that mimics the visible reversed image; spraying the positive impression of the negative cast mold with a mold release agent, at least over a portion thereof including the attachment site; matingly coupling a posterior surface of said sculptured model with said positive impression of the negative cast mold at the prosthesis attachment site; producing a silicone replica of a nipple and areola, coloring said replica, and pushing the replica into said sculptured model; after so positioning said replica, surrounding the coupled positive impression and sculptured model with a containment wall; after said surrounding, casting a negative breast mold of the sculptured model and mounted replica by filling the space bounded by the containment wall with poured plaster; curing and removing the negative breast mold; sanding smooth an inner surface of the negative breast mold, and sanding smooth the positive impression of the negative cast mold at least at said attachment site; coating the positive impression with a curable material to form a first prosthesis wall; coating the negative breast mold with a curable material to form a second prosthesis wall; juxtaposing the first prosthesis wall and the second prosthesis wall such that the prosthesis walls contact one another and cooperate to enclose a chamber; and bonding the prosthesis walls to one another while they are so juxtaposed, to form an external prosthetic enclosure.

Claim 21

A process for fabricating a custom prosthesis, including: forming a negative cast mold of a portion of a body of a subject including at least a prosthesis attachment site, by covering a desired portion of the body with a first layer of a paste material wherein the desired portion includes a substantially larger area than the area to be treated, and disposing upon the paste material at least one covering layer; forming a positive impression of said negative cast mold by applying at least a first coat of a paste material upon an inner surface of the negative cast mold, and removing the positive impression from the inner surface of the negative cast mold; generating a visible reverse image of a desired aspect of the body to be replicated, based on parameters measured from at least one member selected from the group consisting of an existing section of the body to be replicated and a reshaped surrogate of said section; simulating the visible reversed image to form a sculptured model that mimics the visible reversed image; spraying the positive impression of the negative cast mold with a mold release agent, at least over a portion thereof including the attachment site; matingly coupling a posterior surface of said sculptured model with said positive impression of the negative cast mold at the prosthesis attachment site; producing a silicone replica of a nipple and areola, coloring said replica, and pushing the replica into said sculptured model; after so positioning said replica, surrounding the coupled positive impression and sculptured model with a containment wall; after said surrounding, casting a negative breast mold of the sculptured model and mounted replica by filling the space bounded by the containment wall with poured plaster; curing and removing the negative breast mold; sanding smooth an inner surface of the negative breast mold, and sanding smooth the positive impression of the negative cast mold at least at said attachment site; coating the positive impression with a curable material to form a first prosthesis wall; coating the negative breast mold with a curable material to form a second prosthesis wall; juxtaposing the first prosthesis wall and the second prosthesis wall such that the prosthesis walls contact one another and cooperate to enclose a chamber; and bonding the prosthesis walls to one another while they are so juxtaposed, to form an external prosthetic enclosure.

Claim 22

The process of claim 19, further including: drilling said positive impression, after said sanding, to define a first passage extending from a back surface of the positive impression to the prosthesis attachment site; drilling a second passage into an edge of the positive impression to define an air passage that communicates with the first passage.

Claim 23

The process of claim 20 further including: filling the chamber with a silicone gel material by injecting the gel material through the first passage; covering and sealing the first passage; and separating the negative breast mold from the positive impression.

Claim 24

The process of claim 19 further including: forming an inlet passage extending from an outer surface of the sculptured model to the chamber; connecting the inlet passage with a communication passage to allow passage of a medium therethrough; and injecting said medium.