Integrating 3D Scans and CAD Tools for Custom-Fit Wearable Health Monitoring Systems - 25.43
Title:
Integrating 3D Scans and CAD Tools for Custom-Fit Wearable Health Monitoring Systems
Authors:
Pulkit MISHRA, Clara EMMERLING
Textilforschungsinstitut Thueringen-Vogtland e. V., Greiz, Germany
Keywords:
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Abstract:
Emerging healthcare technologies are increasingly incorporating smart textiles to enable non-invasive, real-time health monitoring while reducing healthcare costs. A key innovation is the ECG-smart shirt—an intelligent garment embedded with sensors to track vital signs such as heart activity. For such wearables to function effectively, accurate sensor placement and user comfort are critical. This study presents a digital design workflow that combines 3D body scanning and 2D pattern generation to enable rapid prototyping of custom-fit smart garments adaptable to diverse body types.
The method utilizes Rhinoceros (Rhino) and its generative design plugin, Grasshopper, to automate the development of a sleeveless ECG-smart shirt. The workflow is divided into two concurrent tasks: importing high-resolution 3D body scan meshes containing anthropometric data and sensor landmarks, and constructing a garment pattern using traditional flat-pattern drafting methods. The body scan mesh is then aligned with a reference human model to identify garment contact zones with the skin, which are essential for precise sensor integration.
To transfer geometric data from a standardized reference mesh to individual body scans, the Grasshopper component MeshMap is used. It efficiently maps curve geometries between meshes with differing topologies by identifying corresponding points based on proximity, enabling the reuse of a single reference model across multiple body types.
These mapped zones are flattened into high-density UV maps (over 10,000 points), representing areas of tight garment-to-skin contact. Simultaneously, the constructed garment pattern is flattened into a 2D UV space with a 100x100 vertex grid. By comparing sensor landmark positions in both UV spaces, the method ensures accurate and low-distortion translation of sensor locations from the 3D mesh to the 2D textile layout.
In parallel, advances in CAD-based knitting technology are employed to fabricate garments that conform closely to the body, integrating complex 3D forms and embedded sensor pathways. This digital pipeline also supports user-specific modifications and virtual visualization, enhancing design precision and personalization.
By integrating 3D scanning, digital pattern generation, and generative design tools, this approach provides a fast, scalable, and precise method for producing wearable health-monitoring garments. It reduces prototyping time, improves fit and function, and enables the seamless translation of digital body models into ready-to-manufacture textile designs. The result is a flexible framework for the development of smart garments tailored for telemedicine, personalized health monitoring, and next-generation healthcare delivery.
Abstract:
Presentation:
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How to Cite (MLA):
P. Mishra and C. Emmerling, "Integrating 3D Scans and CAD Tools for Custom-Fit Wearable Health Monitoring Systems", Proceedings of 3DBODY.TECH 2025 - 16th International Conference and Expo on 3D/4D Body Scanning, Data and Processing Technologies, Lugano, Switzerland, 21-22 Oct. 2025, #43
Details:
Proceedings: 3DBODY.TECH 2025, 21-22 Oct. 2025, Lugano, Switzerland
Paper/Presentation: #43
DOI: -
License/Copyright notice
Proceedings: © Hometrica Consulting - Dr. Nicola D'Apuzzo, Switzerland, hometrica.ch.
Authors retain all rights to individual papers, which are licensed under a Creative Commons Attribution 4.0 International License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
The papers appearing in the proceedings reflect the author's opinions. Their inclusion in the proceedings does not necessary constitute endorsement by the editor or by the publisher.
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