Flexible three-dimensional camera-based reconstruction and calibration of tracked instruments

Navigated instruments commonly include applied parts, e.g. burrs or saw blades, that need to be calibrated with respect to the attached or integrated tracker. Since this calibration has to be very precise, it is often performed by the manufacturer. However, due to the great variety of instruments and the option to exchange the applied parts (e.g. burrs) there is a definite demand for flexible and generic calibration techniques. Furthermore, if we look into the medical field, there is also a need for calibrating sterile instruments. We propose a new and flexible camera-based calibration technique that addresses these demands by working contactlessly, precisely, and generically for a large variety of tracked instruments. This is realized using one or more tracked cameras which are calibrated with respect to an attached or integrated tracker. The tracked instrument is rotated in front of the camera(s) and its 3D geometry and surface are reconstructed from the 2D images in the coordinate system of the attached or integrated tracker. The 3D geometry of the navigated instrument was reconstructed with an accuracy of under 0.2 mm. The radius of a sphere-shaped instrument was reconstructed with an RMS deviation of 0.015mm.