Thresholding – From the CT images, the face, respirator, and the air-gap between them were tagged separately based on the variations in pixel intensities (in Hounsfield units).
Region growing – The tagged pixels belonging to each of the three regions of interest (face, respirator, and the air-gap) were separated using a ‘region growing’ operation. Thresholding and region growing complete the segmentation portion of the image processing.
Reconstruction – Following segmentation, the 2D image was reconstructed into a 3D stereolithographic (STL) volume representing the desired geometry.
Post-processing – The geometry in the STL file was subjected to additional wrapping and smoothing operations while ensuring that the gaps and contact points between the face and respirator were unaffected during post-processing. An image of the reconstructed and post-processed 3D CAD model is shown in Fig.