Verlinden told Reuters: "You really want to have someone like that fixed in the right position and you need to have an instant 3D scan of that. We used a system based on photogrammetry, so taking a lot of pictures with a high-resolution camera, an SLR camera, and we had a rig with 150 of these cameras which took one picture completely at the same time, and from that we could reconstruct a 3D model."
The mannequin was constructed using an inexpensive 3D printing method. This consisted of turning two household 3D printing machines on their head, so they could print up to two meters high, producing Dumoulin's replica in eight separate parts. It took a total of 50 hours to print, before each part was attached via simple pin-and-hole joints.
"It (the printer) uses plastic wire, which is extruded like a glue gun and then it's being drawn on the flat surface below, at a tenth of a millimeter or less, and in that way layer by layer you draw these kind of plastic curves," explained Verlinden.
The suit was originally made for Dumoulin's participation in this summer's Tour de France and Olympic Games in Rio. Speaking before the two events, he explained his hopes for the skinsuit. "In cycling, and especially in time trialling, it's about seconds, and even if we get only a little difference with a faster suit it will make a big difference maybe in the result," he said.
Unfortunately, an accident meant Dumoulin had to withdraw from the Tour at stage 19, but his Olympic performance was a happier experience, with him finishing second in the time trial behind Fabian Cancellara.
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