Accurate Reconstruction of Gas Turbine Blade Geometry Using 3D/2D Rigid Registration and CT View Optimization

Accurate registration of CAD models to CT scans is essential for establishing ground truth geometry in volumetric imaging. Obtaining reliable object masks is of growing importance in machine learning settings; as recent architectures grow more capable, huge datasets are required to fully utilise their capabilities. Traditional intensity-based methods fail when CT grayscale values lack calibration references, while point-based algorithms (e.g., ICP, RANSAC) require feature correspondence unavailable between idealized CAD geometry and noisy volumetric CT data. We propose a two-stage geometric registration method for cylindrical objects (ionization chambers) that takes advantage of the distinctive geometric features of the objects. First, we estimate the 3D rotation axis by detecting elliptical cross-sections across CT slices, fitting ellipses to edge-detected contours, and performing PCA on the fitted ellipse centers after RANSAC outlier removal. Second, we voxelize the CAD model, orient it along the detected axis, and maximize volumetric overlap with the CT scan through translational adjustment. This approach achieves robust registration with tilt and orientation errors below $0.1^\circ$ without intensity calibration or feature matching. Once registered, the aligned CAD model provides ground truth geometry for applications including machine learning-based object localization and automated analysis in industrial CT workflows.

Recovering the 6-DoF pose of the knee bones from a plain radiograph, given the patient's segmented pre-operative CT, turns a routine low-dose image into a quantitative measurement of joint geometry, without the added dose of a repeat CT or a fixed biplanar rig. Classic solutions align a rendered bone silhouette to image edges; recent alternatives refine pose by backpropagating an image-similarity loss through a differentiable X-ray renderer. Both operate one patient at a time and are fragile under a single view. Silhouettes are depth-ambiguous, and differentiable-rendering refinement has a narrow capture range at substantial per-iteration cost. We instead learn an amortized, subject-agnostic dense 2D-3D correspondence, supervised solely by projection geometry. One shared-weight model per bone, trained across 758 patients, registers patients unseen during training. The pose then follows in closed form from a global, initialization-free, render-free PnP+RANSAC solve. Because X-ray formation is transmissive, our correspondence target is transmission-aware rather than tied to a single surface. Though trained only to register, the representation is anatomically semantic: a simple classifier reads a landmark's anatomical region from its embedding across held-out patients, and the same features separate the knee's bones into a 2D-3D-consistent identity learned without any bone label. On a large single-institution cohort the model generalizes well to held-out patients.

Rib fractures are common and time-consuming to localize on computed tomography (CT). We ask whether fractures detected independently in two orthogonal CT-derived projections (anteroposterior and lateral) can be paired across views and triangulated into reliable 3D points at a controlled rate of false outputs, and we answer it with a staged diagnostic study. The projection geometry is exact, and given correct correspondence, localization is accurate (median 4.0 mm, 88% within 10 mm, 93.6% rib-exact). On a sealed 55-case cohort, a large share of fractures is in principle recoverable (61.1% dual-view availability, and a correct pair present in the candidate graph for 58.4% of fractures), yet the binding limitation is neither geometry nor localization but confidence-limited cross-view correspondence. A controlled detector-by-correspondence factorial attributes the operational gain to lateral-detector quality rather than the tested matching methods; retraining the lateral detector produces the first nonzero controlled-budget reconstructions. Under a deliberately conservative commitment policy, a pre-specified sealed pass promotes 15 of 601 fractures to correct 3D localizations at 0.436 false points per case (2.50% end-to-end commitment yield), and committed points are accurate (median 1.49 mm, 93% rib-exact). The low yield is a consequence of confidence-gated abstention, not of geometry or detection: the study establishes a reproducible framework for selective 3D localization and identifies cross-view correspondence as the dominant operational bottleneck.