US Patent 8406508 Reproducible three dimensional vacuum forming technique

A method of reproducing a three dimensional (3D) image by counter-distorting a two dimensional (2D) image prior to vacuum forming. A captured or obtained image of a subject is digitalized into 3D and 2D formats and used to create a 3D surface using a CNC machine. A standardized grid pattern with numerous reference points is printed on a vacuum formable material and vacuum formed on the 3D surface representing a subject. The reference points on the grid are displaced during the vacuum forming process due to the 3D nature of the surface. If the image of the subject were printed on the vacuum formable material, it would appear distorted. The displaced reference points are observed and the data is entered into the inventive software which generates a new image with compensated morphological changes. When the new image is vacuum formed on vacuum formable material under the same conditions, the new image would not appear distorted and would accurately depict the subject in 3D.