A locking system that secures a dental model and techniques for separating thermoformed material from dental models

Abstract

The present disclosure discusses techniques and systems for separating dental models (101) from a thermoformed film (1001). A separation system can include a separator unit with one or more separator rods (1303) extending from the separator unit. The separator rods can fit within channels formed within the dental model and can be used to pull the dental model apart from a thermoplastic film that is thermoformed over the dental model.

Description

International Application OR4158PWO TECHNIQUES FOR SEPARATING THERMOFORMED MATERIAL FROM DENTAL MODELS Cross Reference to Related Applications

[0001] This application claims priority to and benefit of U.S. provisional application number 63 / 548,670, filed February 1, 2024, and entitled “Aligner Demolding Device and Automation Method.” This application also claims priority to and benefit of U.S. provisional application number 63 / 720,385, filed November 14, 2024, and entitled “Techniques for Separating Thermoformed Material from Dental Models.” The contents of both U.S. provisional application numbers 63 / 548,670 and 63 / 720,385 are incorporated herein by reference in their entireties. Field of the Technology

[0002] The present technology relates to dental appliance manufacturing techniques. More specifically, this technology relates to techniques for removing thermoformed aligners from models. Background

[0003] Orthodontic aligners are appliances intended to make a series of discrete tooth position corrections aimed at aligning the teeth correctly. The manufacture of aligners traditionally begins with generating a digital model of the patient’s dental arch, either by scanning the patient’s teeth, or by making a dental impression of the patient’s teeth and then scanning the impression. When an intra-oral scanning device (IOS device) is used to scan a patient’s teeth, three-dimensional computer aided design (CAD) representations can be imported by custom software. Alternatively, a mold of the patient’s teeth can be constructed from an impression and scanned with a tabletop scanner. The custom software allows the operator to move individual teeth in specific and discrete movements to achieve the final dental arch of aligned teeth.

[0004] Once a digital model of the patient’s dental arch has been acquired, physical dental models can be fabricated (e.g., using 3D printing techniques) to provide a positivemodel of the teeth. The model is washed and then allowed to dry. Once dried, a polymer sheet is thermoformed over the top of the 3D printed arch model.

[0005] The thermoformed part is then laser marked with part identification. The laser marked, thermoformed part is then cut by one of several methods so that the aligner that goes to the customer can be separated from the excess aligner material.

[0006] The aligner may be polished in a part tumbling process to remove burrs and sharp edges. The aligners are inspected and then sealed in bags to be shipped to the customer's orthodontist, or directly to the patient.

[0007] Generally, aligners are manually removed from the model and often manually trimmed as well. If the trimming is done automatically, the aligner is typically trimmed while it is still thermoformed to the model. One system of automatic trimming uses a drill-type trimming system. Drill-type trimming systems use a drill bit to create a cut in the thermoformed aligner to separate the aligner from the model. Drill bit drills, however, can cut into the 3D printed model causing debris and damaging the model. If a laser is used to cut the aligner, this can melt some of the underlying model material and cause some unwanted blending with the aligner material, along with the potential to generate toxic fumes and dust. Summary

[0008] The present technology solves the above problems by separating an orthodontic aligner from a dental model before trimming. Furthermore, the techniques described herein allow for improved separation of the aligner material from the model without damaging or deforming the aligner during separation. With the aligner separated from the model, laser cutting can be performed without worrying about melting the underlying model and that melted material blending with the aligner. Since the underlying model is not damaged, the model can be reused to make additional aligners as needed.

[0009] Another major advantage of the approach of removing the model before trimming is that the process can be automated. This is difficult to do when separating the already trimmed aligners, as the tooth geometries differ for each patient. A standardized process is therefore only conceivable with a very high level of complexity. With the techniques described here, and by separating before trimming, automation is possible with a comparatively simple concept.

[0010] According to one aspect of the present disclosure, a separation system for separating a dental model from a thermoformed film is disclosed. The separation system includes a separator unit with one or more separator rods. The separator rods fit within separator channels formed within a portion of the model.

[0011] In one embodiment, the separation system also includes a clamp platform and a clamp ring. A portion of the thermoformed film is fixed in place between the clamp platform and the clamp ring, and the separator unit is movable with respect to the clamp platform and can tilt with respect to the clamp platform. In one embodiment, the separator unit can tilt at an angle between about 0°-20°, 0°-15°, 0°-10°, or 0°-5° with respect to an upper surface of the clamp platform.

[0012] In one embodiment, the clamp ring includes a closed lid that forms a sealed separation chamber above the thermoformed film when the clamp ring holds the thermoformed film onto the clamp platform. In one embodiment, the sealed separation chamber can be depressurized during separation of the dental model from the thermoformed film.

[0013] According to another aspect of the present disclosure, a thermoform plate for thermoforming a dental appliance is disclosed. The thermoform plate includes a top surface for receiving a dental model, a locating feature extending from the top surface and designed to interface with a locating socket formed within a portion of the dental model, and a raised block feature extending from the top surface and designed to abut the dental model when the locating feature interfaces with the locating socket. In one embodiment, the locating feature includes a spring element (for example a ball spring plunger) that interfaces with the locating socket formed within the dental model. In another embodiment, the spring element applies a force to the dental model at the locating socket to press the dental model firm against the raised block feature. In another embodiment, the raised block feature includes flared portions designed to engage with facets of the dental model when the dental model is pressed against the raised block feature by the spring element. In another embodiment, the raised block feature is dimensioned to define a groove within a thermoformed film, where the groove has an interior geometry designed to receive a separator unit and provide access to one or more separator channels formed within the dental model.

[0014] According to another aspect of the present disclosure, a system is disclosed that includes a dental model of the patient’s dentition, a thermoform plate to secure the dentalmodel during thermoforming, and a separator unit to remove the dental model from a thermoformed film. The dental model includes one or more separator channels formed within the dental model and a locating socket formed within a bottom portion of the dental model. The thermoform plate includes a locating feature extending from a top surface of the thermoform plate and designed to interface with the locating socket formed within the dental model. The thermoform plate also includes a raised block feature extending from the top surface of the thermoform plate and designed to abut the dental model when the locating feature interfaces with the locating socket. The separator unit includes one or more separator rods designed to fit within the separator channels formed within the dental model. In one embodiment, the locating feature includes a spring element that applies a force to the dental model to press the dental model firm against the raised block feature. In another embodiment, the raised block feature includes flared portions designed to engage with facets of the dental model when the dental model is pressed against the raised block feature by the spring element. In one embodiment, the raised block feature is dimensioned to define a groove within a thermoformed film, where the groove has an interior geometry designed to receive the separator unit and separator rods and provide access to the separator channels formed within the dental model. In one embodiment, the system also includes a clamp platform and a clamp ring, and the separator unit can tilt with respect to the clamp platform. In one embodiment, the separator unit can tilt at an angle between about 0°-20°, 0°-15°, 0°-10°, or 0°-5° with respect to an upper surface of the clamp platform. In another embodiment, the clamp ring includes a closed lid that forms a sealed separation chamber above the thermoformed film when the clamp ring holds the thermoformed film onto the clamp platform.

[0015] In an aspect of the present disclosure, a thermoform plate for thermoforming a dental appliance, includes: a top surface for receiving a dental model; and a locating feature configured to interface with a locating socket formed within a portion of the dental model. The thermoform plate also includes a locking system that secures the dental model to the locating feature during use. The locking system comprises at least one spring element and at least one raised block feature. The spring element provides a force against the dental model to push the dental model against the raised block element.

[0016] In one aspect of the present disclosure, a component of the locking system is positioned in a cavity formed in the dental model. For example, a spring element of the locking system can be positioned in the cavity.

[0017] In one aspect of the present disclosure, the raised block feature extends from the top surface of the thermoform plate and is configured to abut the dental model when the locating feature interfaces with the locating socket. The spring element interfaces with the dental model and applies force to the dental model, pushing the dental model against the raised block feature.

[0018] In one aspect of the present disclosure, the spring element is coupled to the locating feature. The spring element interfaces with the locating socket formed within the dental model to press the dental model against the raised block feature.

[0019] In one aspect of the present disclosure, the spring element is positioned within a body of the thermoform plate. The locating feature is coupled to the spring element such that when the locating feature contacts the dental model, the spring element applies a force that presses the dental model against the raised block feature.

[0020] In one aspect of the present disclosure, the locking system includes: a first raised block feature extending from the top surface of the thermoform plate, having at least one spring element and a second raised block feature extending from the top surface of the thermoform plate. During assembly, the dental model is positioned between the first raised block feature and the second raised block feature. The at least one spring element contacts the dental model and pushes the dental model against the second raised block feature.

[0021] In one aspect of the present disclosure, the locking system includes: a first raised block feature extending from the top surface of the thermoform plate, having at least one spring element and one or more static locating features extending from the top surface of the thermoform plate. The dental model includes one or more openings configured to engage the one or more static locating features. During assembly, the dental model is positioned such that the one or more openings engage the one or more static locating features. The at least one spring element contacts the dental model and pushes the dental model against the static locating features.

[0022] In one aspect of the present disclosure, the locking system includes: a first raised block feature extending from the top surface of the thermoform plate and a second raised block feature extending from the top surface of the thermoform plate. The dental mold has a first alignment feature positioned on a front end of the dental mold and a second alignment feature positioned on a back end of the dental mold, opposite to the first alignment feature. The first raised block feature has a shape complementary to the shape of the first alignment feature. The second raised block feature has a shape complementary to the shape of the second alignment feature. Contact of the first and second alignment features with the firstand second raised block features, respectively, inhibits rotation and translational movement of the dental model. The first raised block feature and or the second raised block feature can include a contoured surface configured to engage with a corresponding contoured surface of the dental model.

[0023] In one aspect of the present disclosure, the locking system includes: a first raised block feature extending from the top surface of the thermoform plate and one or more spring elements coupled to the top surface of the thermoform plate. During assembly, the dental model is positioned between the first raised block feature and the one or more spring elements. The one or more spring elements contact the dental model and push the dental model against the first raised block feature.

[0024] In one aspect of the present disclosure, the locking system includes a raised block feature extending from the top surface of the thermoform plate and configured to abut the dental model when the locating feature interfaces with the locating socket. The raised block feature is dimensioned to define a groove within a thermoformed film. The groove has an interior geometry designed to receive a separator support and one or more separator rods and provide access to one or more separator channels formed within the dental model. Brief Description of the Drawings

[0025] The technology will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0026] FIG.1 shows an exemplary dental model with separation channels that have been printed within a portion of the dental model, according to an embodiment of the present disclosure.

[0027] FIG.2 shows a perspective view from below of an exemplary dental model with a locating socket formed within it, according to an embodiment of the present disclosure.

[0028] FIG.3 shows a cross-sectional view of a portion of the dental model including separation channels and a locating socket, according to an embodiment of the present disclosure.

[0029] FIG.4 shows a perspective view from below of a portion of the dental model including the locating socket, according to an embodiment of the present disclosure.

[0030] FIG.5 shows a perspective view of an example thermoform plate including a raised block feature and a locating feature, according to an embodiment of the present disclosure.

[0031] FIG.6 shows a perspective view of an example dental model secured to a thermoform plate including a raised block feature, according to an embodiment of the present disclosure.

[0032] FIG.7 shows an example schematic view of a dental model mounted to a thermoform plate, according to an embodiment of the present disclosure.

[0033] FIG.8 shows a cross-sectional view of an example dental model secured against a raised block feature, according to an embodiment of the present disclosure.

[0034] FIG.9 shows a top view of a polymer material thermoformed over a dental model and a raised block feature, according to an embodiment of the present disclosure.

[0035] FIG.10 shows an example thermoformed material and dental model after being removed from the thermoform plate and locating feature, according to an embodiment of the present disclosure.

[0036] FIG.11 shows an example separator plate with a separator unit having two separator rods, according to an embodiment of the present disclosure.

[0037] FIG.12 shows a top view of a dental model and aligner material assembly being placed on a separator plate, according to an embodiment of the present disclosure.

[0038] FIG.13A shows a cross-sectional side view of a dental model before a separator rod enters a separator channel, according to an embodiment of the present disclosure.

[0039] FIG.13B shows a cross-sectional side view of a dental model after a separator rod enters a separator channel, according to an embodiment of the present disclosure.

[0040] FIG.14A shows a cross-sectional side view of a separation system before the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure.

[0041] FIG.14B shows a cross-sectional side view of a separation system after the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure.

[0042] FIG.15A shows a cross-sectional side view of an alternative separation system after the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure.

[0043] FIG.15B shows a cross-sectional side view of an example separation platform, according to an embodiment of the present disclosure.

[0044] FIG.16 shows a cross-sectional side view of another example separation system before the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure.

[0045] FIG.17 shows a cross-sectional side view of another example separation system before the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure.

[0046] FIG.18A shows an example cross-sectional view of a dental model mounted to a thermoform plate with a locking system according to a first embodiment of the present disclosure.

[0047] FIG.18B shows an example plan view of the dental model of FIG.18A mounted to a thermoform plate.

[0048] FIG.19A shows an example plan view of a dental model mounted to a thermoform plate with a locking system according to a second embodiment of the present disclosure.

[0049] FIG.19B shows an example cross-sectional view of the dental model of FIG.19A mounted to a thermoform plate.

[0050] FIG.20 shows an example plan view of a dental model mounted to a thermoform plate with a locking system according to a third embodiment of the present disclosure.

[0051] FIG.21 shows an example plan view of a dental model mounted to a thermoform plate with a locking system according to a fourth embodiment of the present disclosure.

[0052] FIG.22A shows an example plan view of a dental model mounted to a thermoform plate with a locking system according to a fifth embodiment of the present disclosure.

[0053] FIG.22B shows an example cross-sectional view of the dental model of FIG.22A mounted to a thermoform plate.

[0054] FIG.23A shows an example plan view of a dental model mounted to a thermoform plate with a locking system according to a sixth embodiment of the present disclosure.

[0055] FIG.23B shows an example cross-sectional view of the dental model of FIG.23A mounted to a thermoform plate. Detailed Description

[0056] The present technology includes a system for separating thermoformed material from dental models. When manufacturing dental appliances, such as transparent aligners or splints, a 3D printed model of a patient’s dentition may be used to thermoform a polymeric sheet into the desired shape of the dental appliance. After thermoforming, the 3D printed dental model can be separated from the thermoformed polymeric material so that excess material can be trimmed away, resulting in the desired dental appliance that can be shipped to a patient.

[0057] In one embodiment of the present disclosure, the 3D printed dental model includes one or more channels that are shaped to receive a separator unit. The separator unit can include, in some embodiments, one or more rods designed to enter the channels in the dental model. After a polymer material is thermoformed over the dental model, the dental model and thermoformed material can be placed on a separation device. The separator rods from the separator unit can enter the channels in the dental model to secure the model. In some embodiments, the separator rod can have a substantially circular cross-section, or a rectangular cross-section, or a cross section having another suitable geometry. The separator rod can also include a thin metal beam, or any other suitable structure that protrudes from the separator unit and which can be inserted into a channel or cavity within the dental model.

[0058] In one embodiment, the polymer material extends over the dental model and beyond the footprint of the dental model, and also extends beyond the footprint of the separator plate. In this way, the outer edge of the polymer material can be secured to a portion of a separation system and held in place, while the separator rods can grab the dental model and pull it away from the polymer material.

[0059] In order to provide space for the separator unit and the separator rods to enter the certain separation channels formed within the dental model, the polymer material can be thermoformed on a thermoform plate that includes a raised block feature extending from thesurface of the thermoform plate that blocks out an area or socket within the thermoformed material for the separator rods to enter the separation channels within the dental model.

[0060] In some embodiments, the dental model also includes a locating socket that is shaped to receive a locating feature that extends from the surface of the thermoform plate. This locating feature can include a geometric protrusion that interfaces with the locating socket in the 3D printed dental model in order to hold the dental model in the proper position during thermoforming. One benefit of this locating feature is to secure the dental model in position against the raised block feature that also extends from the thermoform plate in order to ensure that the blocked out groove in the thermoformed material has the correct interior geometry to receive the separator unit so that the separator rods can enter the separation channels within the dental model.

[0061] In one embodiment, the locating feature includes a spring element (for example, a spring plunger), or some other feature that can apply a force to the dental model at the locating socket in order to press the dental model against the raised block feature. The locating feature can include a spring loaded ball plunger, in some embodiments, or some other spring loaded or elastic feature that exerts a force against the dental model at the locating socket. The spring element can compensate for inaccurate placement of the model (for example by a person or a robot) on the thermoforming plate. Due to the spring element and the form fit between the model and the block, the dental models are always pressed to a defined position with high precision. In addition, the locating feature keeps the model in this defined position during thermoforming.

[0062] In some embodiments, the locating socket can be a customized cavity formed within a portion of the dental model specifically designed to receive the locating feature. However, in other embodiments, the dental model can include a cavity formed underneath the tooth portions that is created during the 3D printing process, and this cavity can receive a locating feature, a locking feature, or act as the locating socket. For example, a locating feature with a spring element can interact with the pre-formed cavity in the dental model underneath the front teeth area. In this embodiment, the pre-formed cavity acts as the locating socket.

[0063] In alternative embodiments, the locating feature can include a spring element within the thermoforming plate that can engage with a feature that extends above an uppersurface of the thermoforming plate. This feature that extends above the surface of the thermoforming plate can then transfer a force from the spring element to the dental model.

[0064] In another alternative embodiment, the dental model can include openings that can engage with one or more static features that protrude from the surface of the thermoforming plate, and the block element itself can be spring loaded so that it presses against the dental model.

[0065] In embodiments where thermoforming is performed over a thermoform plate with a raised block feature, after thermoforming the dental model and thermoformed material can be released from the locating feature and removed from the thermoform plate. After removing the dental model and the thermoformed material from the thermoform plate, the dental model can be moved to a separation system that includes a separator unit with separator rods. The removal of the dental model and thermoformed material can be performed by hand, or automatically using a robotic transfer system, in various embodiments. As discussed above, the dental model has been printed with channels configured to receive the separator rods, and the raised block feature has formed a blocked out groove in the thermoformed material so that the separator rods can enter the separation channels. Once the dental model is secured by the separator rods, a clamp ring or lid of the separation system can clamp down on excess aligner material outside the footprint of the dental model, and the separator rods can pull down on the dental model, separating it from the thermoformed aligner material. In some embodiments, the separation system lid can be negatively pressurized in order to help with the separation of the dental model from the aligner material.

[0066] In alternative embodiments, the thermoforming and separation can be performed at a single system where the separator rods hold the dental model in place to allow for accurate thermoforming of the polymeric material over the dental model. In such an embodiment, once the thermoforming is complete, a portion of the base plate below the model can be lowered and the separator rods can pull the dental model away from the aligner material.

[0067] In some embodiments, the separator plate can be pulled directly downward away from the aligner material to pull the dental model apart from the aligner material. However, in alternative embodiments the separator unit (either independently, or along with the separator plate) can be allowed to tilt or lean within a certain range of angles in order to allow more smooth separation of the dental model from the aligner material. Allowing the separatorunit to angulate in this way can improve the separation process and prevent stress damage to the aligner material during separation.

[0068] In some embodiments, a thermoform plate includes a locking system that secures the dental model to the locating feature during use. In one embodiment, a component of the locking system is positioned in a cavity formed in the dental model. For example, a locking system can include a spring element. The spring element, positioned in the dental model, interacts with the dental model and a locating feature or raised block features disposed on the surface of the thermoform plate to secure the dental model to the thermoform plate.

[0069] FIG.1 shows an exemplary dental model 101 with separation channels 103 that have been printed within a portion of the dental model 101, according to an embodiment of the present disclosure. As discussed above, these separation channels 103 can be designed to receive separator rods that can clamp the dental model 101 to a separation plate to separate the model from a polymer material that has been thermoformed over the dental model.

[0070] FIG.2 shows a perspective view from below of an exemplary dental model 101 with a locating socket 105 formed within it, according to an embodiment of the present disclosure. This locating socket 105 can interface with a locating feature on a thermoform plate in order to secure the dental model 101 in place during thermoforming. The locating socket 105 can also be connected to the separation channels 103 in order to assist with drainage of excess resin from within the 3D printed dental model 101 when the dental model 101 is being cleaned after 3D printing and before thermoforming. In the embodiment shown in FIG.2, the dental model 101 is 3D printed to include facets 107 that can help secure the dental model 101 in place against a raised block feature during thermoforming, as discussed in more detail below.

[0071] The example embodiment shown in FIG.2 includes a dedicated locating socket 105 designed to receive a locating feature. However, in other embodiments the dental model can include a tooth cavity 109 formed under the tooth portions of the model during the 3D printing process. This tooth cavity can also function as the locating socket, in some embodiments. Where this tooth cavity functions as the locating socket, a locating feature on the thermoform plate can interact with the tooth cavity and eliminate the need for a separate distinct locating socket.

[0072] FIG.3 shows a cross-sectional view of a portion of the dental model including separation channels 103 and a locating socket 105, according to an embodiment of thepresent disclosure. Preferably, the separation channels 103 are formed within a portion of the dental model within the dental arch model that does not include any portion of the patient’s dentition. This area within the concave portion of the dental arch model is shown in FIG.3 and can form the structure of the separation channels 103 and the locating socket 105. As shown in FIG.3, the separation channels 103 connect with the locating socket 105 to allow for drainage of excess resin during the 3D printing process and during cleaning of the dental model.

[0073] FIG.4 shows a perspective view from below of a portion of the dental model including the locating socket 105, according to an embodiment of the present disclosure. In this view, the facets 107 formed into a portion of the dental model are also visible. These facets can be angled, in some embodiments, in order to help secure the dental model up against a raised block feature during thermoforming.

[0074] FIG.5 shows a perspective view of an example thermoform plate 501 including a raised block feature 503 and a locating feature 507, according to an embodiment of the present disclosure. In this example embodiment, the locating feature 507 is configured to engage with the locating socket 105 within the dental model discussed above (i.e., locating socket 105 of FIG.4). A locking system includes a spring element 509 (e.g., a spring loaded ball plunger) that can extend partially outside the locating feature 507 to securely hold the dental model onto the thermoform plate 501. The raised block feature 503 also includes one or more optional flared portions 505, in some embodiments, that can extend from the sides of the raised block feature 503. When a dental model is positioned onto the thermoform plate 501, the spring element 509 can interact with the locating socket 105 within the dental model and snap the dental model into place on the thermoform plate. The spring element 509 can provide a force against the dental model at the locating socket so that the facets 107 of the dental model are pressed up against the flared portions 505 of the raised block feature 503. This ensures a tight fit between the dental model and the raised block feature 503 so that no polymeric material can enter between the dental model and the raised block feature 503 during thermoforming. This can ensure an unobstructed blocked out area so that separator rods can enter the separator channels after thermoforming. Additionally, a very precise and repeatable positioning of the model can be achieved right before thermoforming using the flared portions 505 and the facets 107. Such accurate positioning here is key for a precise laser trimming later. Finally, mating the dental model facets with the flared portions of theraised block features can prevent or inhibit rotation and translational movement of the dental model during thermoforming.

[0075] FIG.6 shows a perspective view of an example dental model 101 secured to a thermoform plate 501 including a raised block feature 503, according to an embodiment of the present disclosure. In this example embodiment, the dental model 101 has been positioned over the thermoform plate 501 so that the locating feature and spring element connect with the locating socket formed within the dental model 101. The spring element of the locating feature applies a force to the dental model to press the facets 107 up against the flared portions 505 on the raised block feature 503, thus holding the dental model 101 securely in place prior to and during thermoforming.

[0076] In reference to FIGS.5-6, the thermoform plate 501 may include a plurality of holes, which can allow for air to escape that may get trapped between the aligner material and the thermoform plate during the thermoforming process. In some embodiments, a vacuum system can be incorporated into the thermoforming system that can provide a suction through one or more of these holes within the base plate to assist with holding the aligner material and completing the thermoforming. Additional indentations may also be incorporated into the thermoform plate 501 to transfer features in the aligner material that can be useful for transportation, positioning, or alignment at later steps in the manufacturing process.

[0077] FIG.7 shows an example schematic view of a dental model 701 mounted to a thermoform plate 703, according to an embodiment of the present disclosure. In this example diagram, an interior portion of the locating socket of the dental model 701 can include an angled or wedged portion 705 that can interact with a spring element 707 extending from a portion of the thermoform plate 703. This wedged portion 705 can provide a more secure connection with the spring element 707 to press the dental model 701 against the raised block feature 709 of the thermoform plate 703, in some embodiments.

[0078] FIG.8 shows a cross-sectional view of an example dental model 801 secured against a raised block feature 803, according to an embodiment of the present disclosure. In this example view, the dental model 801 is secured to a thermoform plate using a spring loaded spring element 805 that mates with a locating socket formed within the dental model. The spring element 805 applies a force against the dental model 801 to press it securely against the raised block feature 803. The tight contact shown between the dental model 801 and the raised block feature 803 helps ensure an unobstructed blocked out area within thethermoformed sheet so that the separator rods can enter the separator channels of the dental model.

[0079] FIG.9 shows a top view of a polymer material 901 thermoformed over a dental model 903 and a raised block feature 905, according to an embodiment of the present disclosure, to form an orthodontic aligner precursor. The orthodontic aligner precursor includes the orthodontic aligner and excess thermoformed polymer at least partially surrounding the orthodontic aligner. As shown in this example figure, the dental model 903 is held fast against the raised block feature 905 such that the polymer material 901 can thermoform over both the dental model 903 and the raised block feature 905 without a significant portion of the polymer material 901 penetrating between either one. This forms an unobstructed blocked out area within the polymer material 901 where the raised block feature 905 is located.

[0080] The polymer material 901 is a thin thermoformable material that is often substantially transparent or translucent. The thickness of the polymer material 901 is not particularly limited but should be of sufficient thickness to thermoform around a dental model. Preferably, the polymeric material is less than 5 mm thick. More preferably, the thickness of the polymeric material may be from about 0.05 to about 5 mm thick.

[0081] The polymeric material can include, for example, a multilayer polymeric material such as those described in US Patent Number 10,549,511; US Patent Number 10,870,263; US Patent Number 10,987,907; US Patent Number 11,325,358; US Patent Number 10,946,630; US Patent Publication No.2022 / 0118747; PCT Application No. PCT / US2020 / 065928; PCT Application No. PCT / US2022 / 025306; and Provisional US Patent Application No. 63 / 354,998; all of which are incorporated by reference in their entirety.

[0082] When the thermoforming material is exposed to heat, the material becomes more pliable, which allows the material to mold and take the shape of a model when adequate pressure is applied.

[0083] FIG.10 shows an example of the orthodontic aligner precursor which includes the orthodontic aligner 1003 and excess thermoformed polymer 1001 after the orthodontic aligner precursor and dental model 1003 are removed from the thermoform plate and locating feature, according to an embodiment of the present disclosure. After thermoforming, the thermoformed polymer 1001 is attached to the underlying dental model 1003 and must be separated from this model. Separation of the aligner material from the model can be a challenging task, in some cases, especially in challenging cases where the patient’s dentitionincludes overhanging teeth, or in instances where engagers or other treatment techniques are being used. Because the polymer film in this example is thermoformed over the dental model 1003 and the raised block feature of the thermoform plate, when the dental model 1003 and thermoformed material 1001 are removed from the thermoform plate, a blocked out groove 1005 is formed within the thermoformed material 1001. This blocked out groove 1005 provides access to the separator channels 1007 within the dental model 1003 after removal from the thermoform plate.

[0084] FIG.11 shows an example separator plate 1101 with a separator unit 1103 having two separator rods 1105, according to an embodiment of the present disclosure. In this example embodiment, the separator unit 1103 extends from the top surface of the separator plate 1101 and includes two separator rods 1105 that extend from the separator unit 1103 parallel to the surface of the separator plate 1101. As discussed above, the model of the patient’s dentition is 3D printed to include separator channels that can receive the separator rods 1105. Because the aligner material is thermoformed over the dental model as well as the raised block feature of the thermoform plate, there is a blocked out groove or channel within the aligner material that can receive the separator unit 1103, including the separator rods 1105. In some embodiments, the separator plate can be pulled together with the separator unit and separator rods.

[0085] FIG.12 shows a top view of a dental model 1201 and orthodontic aligner precursor 1203 assembly being placed on a separator plate 1205, according to an embodiment of the present disclosure. In this view, the assembly that includes the dental model 1201 and the orthodontic aligner precursor 1203 thermoformed over the model has been placed on the separator plate 1205 so that the separator unit fits within the groove or channel formed within the orthodontic aligner precursor 1203 by the raised block feature. As can be seen, the groove formed within the orthodontic aligner precursor, by the raised block feature, is large enough to enclose the separator unit, including the separator rods, so that the separator rods can align with and then enter the separator channels formed within the dental model 1201.

[0086] FIG.13A shows a cross-sectional side view of a dental model before a separator rod 1301 enters a separator channel 1303; and FIG.13B shows a cross-sectional side view of a dental model after a separator rod 1301 enters a separator channel 1303, according to an embodiment of the present disclosure. The separator rod 1301 is positioned above the surface of the separator plate in order to align with the separator channel 1303 that is formed withinthe dental model. Once the separator rod 1301 enters the separator channel, as shown in FIG. 13B, the dental model is secured to the separator plate.

[0087] FIG.14A shows a cross-sectional side view of a separation system 1400 before the dental model is separated from the orthodontic aligner precursor, according to an embodiment of the present disclosure. In this example embodiment, the separation system 1400 includes a separator plate 1401, one or more separator rods 1403 designed to insert within separator channels in a dental model, and a clamping system. The clamping system includes a clamp platform 1405 and a clamp ring 1407. In this embodiment, when an assembly including a dental model and orthodontic aligner precursor is secured to the separator plate 1401 using the separator rods 1403, the excess thermoformed polymer 1409 extends beyond the footprint of the separator plate 1401 and onto the clamp platform 1405. The clamp ring 1407 can then be secured over both a portion of the excess thermoformed polymer 1409 and a portion of the clamp platform 1405 to secure the aligner material 1409 onto the clamp platform 1405. In the embodiment shown in FIG.14A, the clamp ring 1407 is a closed lid that can form a sealed separation chamber 1411 above the orthodontic aligner precursor. In embodiments where the clamp ring 1407 includes a closed lid, the sealed separation chamber 1411 can be depressurized in order to assist with the separation of the orthodontic aligner precursor from the dental model.

[0088] FIG.14B shows a cross-sectional side view of a separation system 1400 after the dental model is separated from the thermoformed aligner material, according to an embodiment of the present disclosure. In the example shown in FIG.14B, the separator plate 1401 has been retracted downward, perpendicular to the top surface of the separator plate 1401. Because the thermoformed orthodontic aligner precursor is clamped in place between the clamp platform 1405 and the clamp ring 1407, the orthodontic aligner precursor remains substantially in place while the dental model is pulled downward by the separator rods 1403. One skilled in the art will appreciate that the downward force pulling the separator plate 1401 and / or separator unit can be achieved by any suitable mechanical power source. As discussed above, in optional embodiments where the clamp ring 1407 includes a closed lid, a negative pressure within the sealed separator chamber 1411 can assist with the separation. Once the dental model has been separated from the orthodontic aligner precursor, the clamp ring 1407 can be removed to release the orthodontic aligner precursor for further processing (e.g., trimming, inspection, packaging, etc.).

[0089] FIG.15A shows a cross-sectional side view of an alternative separation system 1500 after the dental model is separated from the orthodontic aligner precursor, according to an embodiment of the present disclosure. In the example shown in FIG.15A, the separation system includes a separator plate 1501 that can tilt or lean with respect to the clamp platform. In some embodiments, the separator plate can tilt in any desired direction in order to reduce stresses applied to the orthodontic aligner precursor during separation. In one example embodiment, the separator plate 1501 can tilt within a certain range of angles in order to allow more smooth separation of the dental model from the orthodontic aligner precursor. Allowing the separator plate 1501 and / or separator unit to angulate in this way can prevent stress damage to the orthodontic aligner precursor during separation. In some embodiments, the separator plate 1501 can tilt at angles between about 0° to about 20°, or between about 0° to about 15°, or between about 0° to about 10°, or between about 0° to about 5°, with respect to the upper surface of the clamp platform 1505. The ability of the separator plate 1501 to tilt slightly can improve separation, especially on complex cases with overhanging teeth, bite ramps, engagers, or other orthodontic features. The tilting ability of the separator plate 1501 can be achieved in a number of different ways, including having one or more spring-loaded supports underneath the separator plate 1501 that can compress or extend depending on which portions of the aligner material have gripped more strongly to the dental model. In one embodiment, the separator plate 1501 can be pulled downward by a central force that is located substantially at the center of the separator plate 1501, and two or more spring-loaded supports can be arranged around the edge and underneath of the separator plate. As the separator plate 1501 is pulled downward, it can tilt within a certain range of angles in order to more smoothly ease the dental model out from the orthodontic aligner precursor.

[0090] FIG.15B shows a cross-sectional side view of an example separation platform, according to an embodiment of the present disclosure. In this example embodiment, the separator plate 1501 can be supported from below by flexible support structures 1511 that allow the separator plate 1501 to tilt or angulate while the dental model is being separated from the thermoformed film. In some embodiments, the flexible support structures 1511 can include two or more spring loaded supports below the separator plate. The flexible support structures 1511 can include telescoping cylinders that house springs, in some embodiments. In the example shown in FIG.15B, two cylindrical spring loaded flexible support structures 1511 are shown on opposite sides of the separator plate 1501. However, additional designsfor the flexible support structures 1511 can be implemented, and more or fewer flexible support structures can be used and arranged in different locations or patterns.

[0091] FIG.16 shows a cross-sectional side view of another example separation system 1600 before the dental model is separated from the orthodontic aligner precursor, according to an embodiment of the present disclosure. In this example embodiment, the separation system 1600 includes a separator plate 1601, one or more separator rods 1603 designed to insert within separator channels in the dental model and a clamping system. The clamping system includes a clamp platform 1605 and a clamp 1607. In the example embodiment shown in FIG.16, the clamp 1607 does not include a closed lid (as opposed to the example embodiment shown in FIGS.14A-14B). The clamp 1607 can be an annular ring that clamps down on excess thermoformed polymer 1609 at the clamp platform 1605. In other embodiments, the clamp 1607 can have a rectangular footprint, or any other suitable geometry, and is not necessarily cylindrical.

[0092] FIG.17 shows a cross-sectional side view of another example separation system 1700 before the dental model is separated from the orthodontic aligner precursor, according to an embodiment of the present disclosure. In this example embodiment, the separation system 1700 does not include a separator plate, but instead functions with a separator unit 1711 that includes one or more separator rods 1703 extending from it and designed to insert within separator channels within the dental model. Once the separator rods 1703 engage with the dental model, the separator unit 1711 can apply an extraction force to the dental model to pull it out of the orthodontic aligner precursor. The separation system 1700 also includes a clamping system. The clamping system includes a clamp platform and a clamp ring 1707. Excess thermoformed polymer 1709 extends beyond the footprint of the separator rods 1711 and onto the clamp platform. The clamp ring 1707 can then be secured over both a portion of the excess thermoformed polymer 1709 and a portion of the clamp platform to secure the aligner material 1709 onto the clamp platform. In the embodiment shown in FIG.17, the clamp ring 1707 is a closed lid that can form a sealed separation chamber 1711 above the orthodontic aligner precursor. In embodiments where the clamp ring 1707 includes a closed lid, the sealed separation chamber 1711 can be depressurized in order to assist with the separation of the orthodontic aligner precursor from the dental model.

[0093] FIG.18A shows an example cross-sectional view of a dental model 1801 mounted to a thermoform plate 1803, according to an embodiment of the present disclosure. In this example embodiment, the locking system includes a raised block feature 1809 extendingfrom the top surface of the thermoform plate and configured to abut the dental model when the locating feature interfaces with the locating socket. The locking system also includes a spring element that interfaces with the dental model and applies force to the dental model, pushing the dental model against the raised block feature. In this embodiment, the locating feature 1807 can extend above an upper surface of the thermoform plate and can engage with a spring element 1805 within the thermoform plate 1803. The locating feature 1807 can interface with a locating socket 1811 formed in a portion of the dental model. The spring element acts as a locking system by transferring a force to the locating feature 1807. The force on the locating feature 1807, pushes the locating feature in contact with the locating socket 1811, which presses the dental model up against the raised block feature 1809. FIG. 18B shows a top view of the locking system depicted in FIG.18A. FIG.18B shows that there can be two locating features 1807 that align with corresponding locating sockets 1811.

[0094] FIG.19A shows an example plan view of a dental model 1901 mounted to a thermoform plate 1903 with a locking system, according to an embodiment of the present disclosure. In this view, the locking system includes a spring loaded raised block feature 1909 and one or more static locating features 1905. The dental model 1901 includes one or more openings 1907 that can engage with one or more static locating features 1905 that extend from the surface of the thermoform plate 1903. The thermoform plate 1903 can also include a raised block feature 1909 that includes a spring element 1911 that presses the raised block feature against the dental model 1901. During use, the dental model is positioned such that the one or more openings 1907 engage the one or more static locating features 1905. The spring-loaded raise block feature 1909 contacts the dental model and pushes the dental model against the static locating features to lock the model onto the thermoform plate. The raised block feature includes a contoured end 1915 which has a shape that is complementary with a countered locating socket 1917 in the dental model. Mating the raised block feature contoured end 1915 with the contoured locating socket 1917 of the dental model can prevent or inhibit rotation and translational movement of the dental model during thermoforming and other processing steps.

[0095] FIG.19B shows an example cross-sectional view of the dental model 1901 of FIG.19A mounted to a thermoform plate 1903 with a locking system, according to an embodiment of the present disclosure. In this example shown in FIG.19A and FIG.19B, the spring loaded raised block feature 1909 and one or more static locating features 1905 is shown pressed against a portion of the dental model 1901 so that the raised block feature1909 and the dental model 1901 are held fast against each other. During use, the polymer material can be thermoformed over both without a significant portion of the polymer material penetrating between either one. This forms an unobstructed blocked out area within the thermoformed polymer material where the raised block feature 1909 is located.

[0096] FIG.20 shows an example top view of a dental model 2001 mounted to a thermoform plate 2003, according to an embodiment of the present disclosure. In this example embodiment, the locking system includes a first raised block feature 2005 extending from the top surface of the thermoform plate. The first raised block feature includes two spring elements 2007. A second raised block feature 2009 also extends from the top surface of the thermoform plate. The dental mold includes a first alignment feature 2017 positioned on a front end of the dental mold and a second alignment feature 2021 positioned on a back end of the dental mold, opposite to the first alignment feature. The first raised block feature has an indentation 2015 complementary to the shape of the first alignment feature 2017. The second raised block feature has an indentation 2019 complementary to the shape of the second alignment feature 2021. During assembly, the dental model is positioned between the first raised block feature and the second raised block feature. The first alignment feature 2017 is mated with the indentation 2015 of the first raised block feature. The second alignment feature 2021 is mated with the indentation 2019 of the second raised block feature. Two spring elements contact the dental model at the first alignment feature and push the dental model against the second raised block feature. Mating the indentations of the raised block features with the alignment features of the dental model can prevent or inhibit rotation and translational movement of the dental model during thermoforming and other processing steps.

[0097] FIG.21 shows an example top view of a dental model 2101 mounted to a thermoform plate 2103, according to an embodiment of the present disclosure. In this example embodiment, the locking system includes a first raised block feature 2105 extending from the top surface of the thermoform plate. The first raised block feature includes a spring element 2107. A second raised block feature 2109 also extends from the top surface of the thermoform plate. The dental mold includes a conical alignment feature 2117 positioned on a front end of the dental mold and a second alignment feature 2121 positioned on a back end of the dental mold, opposite to the first alignment feature. The second raised block feature has shape 2119 complementary to the shape of the second alignment feature 2121. During assembly, the dental model is positioned between the first raised block feature and the secondraised block feature. The spring element on the raised block feature is mated with the conical alignment feature on the dental model. The second alignment feature 2121 is mated with the indentation 2119 of the second raised block feature. The use of a conical indentation provides more tolerance to lock the dental model onto the thermoform plate. Additionally, the conical indentation allows the dental model to be snapped into place. During assembly, the dental model can contact the spring element at an angle. The conical indentation in the dental model allows rotation and translational movement of the dental model onto the thermoform plate.

[0098] FIG.22A shows a top view of a dental model 2201 mounted to a thermoform plate 2203, according to an embodiment of the present disclosure. FIG.22B shows a cross- sectional view of the locking system. In this example embodiment, the locking system includes a movable first raised block feature 2205, a movable second raised block feature 2209, and a spring element 2207. The first raised block feature 2205 includes an optional spring element 2206 which provides a force to the first raised block feature that pushes the feature against the dental model. The second raised block feature 2209 is partially embedded in a cavity formed in the thermoform plate, with a portion of the second raised block feature extending from the top surface of the thermoform plate. The spring element 2207 is coupled to the second raised block feature and also embedded in the cavity of the thermoform plate. The second raised block feature also includes a passageway 2211 to receive guide rod 2212. The ends of guide rod are embedded in the thermoform plate. The guide rod prevents the second raised block from coming out of the thermoform plate, while ensuring that the second raised block moves linearly along the passage formed in the thermoform plate. The dental mold includes a first alignment feature 2217 positioned on a front end of the dental mold. The first raised block feature has an indentation 2015 complementary to the shape of the first alignment feature 2217. A cap 2219 is present on the portion of the second raised block feature that extends from the thermoform plate. The cap is positioned to cover any gaps that form between the second raised block feature and the cavity when the dental mold is locked onto the thermoform plate. During assembly, the dental model is positioned between the first raised block feature and the second raised block feature. The first alignment feature 2217 is mated with the indentation 2215 of the first raised block feature. The second raised block feature contacts the dental mold, pushing the dental mold toward the first raised block feature. This embodiment has an advantage over other embodiments, by positioning the locking system underneath the dental mold. Positioning the locking system underneath thedental mold prevents all or most of the locking system from being covered with the thermoform polymer.

[0099] FIG.23A shows a top view of a dental model 2301 mounted to a thermoform plate 2303, according to an embodiment of the present disclosure. FIG.23B shows a cross- sectional view of the locking system. In this example embodiment, the locking system includes a spring element 2305 coupled to the thermoform plate 2303 and a raised block feature 2309. As discussed above, a thermoform plate includes a locating feature that is configured to interface with a locating socket formed within a portion of the dental model. In this embodiment the spring element 2305 acts as the locating feature. The spring element 2305 interfaces with the locating socket 2311, formed on the dental model to press the dental model against the raised block feature 2309. The dental mold includes an alignment feature 2317 positioned on a back end of the dental mold. The raised block feature has a shaped end 2315 that is complementary to the shape of the alignment feature 2317. During assembly, the dental model is positioned over the locating feature, such that the spring element contacts the locating socket of the dental model. The spring element pushes the dental model toward the raised block feature, locking the dental model onto the thermoform plate. The locating socket can have an indented or conical shape that is configured to receive the spring element.

[0100] In one embodiment, the present technology includes a method of making an orthodontic aligner. The method begins by preparing a dental model for thermoforming. Dental models may be made by printing a 3D model. This model may include a positive model of a dental arch and may also include a 3D printed locating socket in some embodiments.

[0101] A thermoform plate having locating features and locking features as described herein is next provided for securing the dental model to the thermoform plate. A locating feature can include any feature that assists in locating and securing the dental model to the plate. A locking feature can include any feature that secures the dental model to the thermoform plate. The thermoform plate may also include locator cones, which are concave conical indentations in the locator plate, that further assist in aligning the locator plate correctly.

[0102] Once the dental model is secured to the thermoform plate and in the proper position, the thermoforming material may be thermoformed over the dental model. The thermoforming material is preferably a polymer / thermoplastic sheet or film that is biocompatible and moldable over dental models once sufficient heat and / or pressure isapplied. The thermoformed polymer is placed over the entire thermoform plate, encapsulating the dental model, the locating socket, the locating feature, and the holding element.

[0103] The next step in the process is to separate the thermoformed polymer from the dental model / thermoform plate. In one aspect of the present disclosure, the dental model is removed from the thermoform plate by unlocking the dental model from the locking system. The unlocked dental model, with the attached orthodontic aligner precursor, is then transferred to the separation system, where the orthodontic aligner precursor is automatically separated from the dental model. Preferably, the dental model / orthodontic aligner precursor is conveyed to the separation system without any contact with the orthodontic aligner. The only contact made during transport is with the excess thermoformed material.

[0104] In one aspect of the present disclosure, the separation system includes a separation plate. The separation system includes a separation plate having one or more separator rods. The separation system also includes a clamping system. The clamping system includes a clamp platform and a clamp ring.

[0105] The dental model / orthodontic aligner precursor is attached to the separation plate by positioning one or more separator rods within the one or more separator channels formed within the dental model. After the dental model / orthodontic aligner precursor is attached to the separation plate the excess thermoformed polymer can be positioned between the clamp platform and the clamp ring. To remove the orthodontic aligner precursor from the dental model, the separation plate is moved away from the clamp platform. The mold is carried with the separation plate, leaving the orthodontic aligner precursor connected to the clamping system.

[0106] In an aspect of the present disclosure, the separation system includes clamp ring having a sealed separation chamber. Once positioned in the separation system the clamp ring contacts a portion of the excess thermoformed polymer of the orthodontic aligner precursor. A vacuum is created within the sealed separation chamber to fix the excess thermoformed polymer to the clamp ring. In some embodiments, the pressure within the sealed separation chamber is reduced a sufficient amount to hold the orthodontic aligner precursor in place during the separation process. Once the orthodontic aligner precursor is secured, the thermoform plate is moved away from the clamp platform, separating the orthodontic aligner precursor from the dental model. The locking system secures the dental model against the thermoform plate to inhibit the dental model from being pulled off the thermoform plate during the separation process.

[0107] The techniques described herein allow for thermoforming and separation without imparting any features of the separation unit onto the thermoformed polymer material. According to some separation techniques, an anchoring device may be placed over a portion of the dental model before thermoforming, so that after thermoforming the anchoring device can pull the dental model away from a thermoformed sheet. However, this imparts a feature of the anchoring device onto the thermoformed sheet. According to one embodiment, the raised block feature of the thermoform plate, along with the separator rods designed to enter separation channels within the dental model, allows for separation of the dental model from the thermoformed sheet without imparting any feature of the separator unit onto the thermoformed sheet.

[0108] The separated thermoformed polymer includes the orthodontic aligner attached to the excess thermoformed polymer that covered the thermoform plate. The orthodontic aligner is then cut from the orthodontic aligner precursor. The orthodontic aligner can be cut from the thermoformed polymer using a mechanical or laser cutting device.

[0109] In one aspect of the present disclosure, the cutting system comprises a support plate having a locating feature extending from a top surface of the thermoform plate. The orthodontic aligner precursor includes a locating socket having a shape complementary to the locating feature. The orthodontic precursor is positioned on the cutting system support plate such that the locating socket mates with the locating feature on the support plate prior to cutting. The locating socket of the orthodontic aligner precursor is formed from the polymer sheet that contacts the locating feature of the dental model. Use of a locating feature on a platform of the cutting system, can ensure that the orthodontic aligner precursor is properly aligned on the cutting system platform prior to cutting.

[0110] Specific embodiments and methods of securing thermoforming models have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Claims

CLAIMS What is claimed is:

1. A thermoform plate for thermoforming a dental appliance, comprising: a top surface for receiving a dental model; a locating feature configured to interface with a locating socket formed within a portion of the dental model; and a locking system that secures the dental model to the locating feature during use, wherein the locking system comprises at least one spring element and at least one raised block feature; wherein the spring element provides a force against the dental model to push the dental model against the raised block element.

2. The thermoform plate of claim 1, wherein a component of the locking system is positioned in a cavity formed in the dental model.

3. The thermoform plate of claim 2, wherein the spring element is positioned in the cavity.

4. The thermoform plate of claim 1, wherein the raised block feature extends from the top surface of the thermoform plate and is configured to abut the dental model when the locating feature interfaces with the locating socket; and wherein the spring element interfaces with the dental model and applies force to the dental model, pushing the dental model against the raised block feature.

5. The thermoform plate of claim 4, wherein the spring element is coupled to the locating feature, and wherein the spring element interfaces with the locating socket formed within the dental model to press the dental model against the raised block feature.

6. The thermoform plate of claim 4, wherein the spring element is positioned within a body of the thermoform plate, and wherein the locating feature is coupled to the spring element such that when the locating feature contacts the dental model, the spring element applies a force that presses the dental model against the raised block feature.

7. The thermoform plate of claim 1, wherein the locking system comprises: a first raised block feature extending from the top surface of the thermoform plate, comprising at least one spring element; a second raised block feature extending from the top surface of the thermoform plate; wherein the dental model is positioned between the first raised block feature and the second raised block feature, and wherein the at least one spring element contacts the dental model and pushes the dental model against the second raised block feature.

8. The thermoform plate of claim 1, wherein the locking system comprises: a first raised block feature extending from the top surface of the thermoform plate, comprising at least one spring element; one or more static locating features extending from the top surface of the thermoform plate; wherein the dental model comprises one or more openings configured to engage the one or more static locating features; wherein the dental model is positioned such that the one or more openings engage the one or more static locating features, and wherein the at least one spring element contacts the dental model and pushes the dental model against the static locating features.

9. The thermoform plate of claim 1, wherein the locking system comprises: a first raised block feature extending from the top surface of the thermoform plate; a second raised block feature extending from the top surface of the thermoform plate; wherein the dental mold has a first alignment feature positioned on a front end of the dental mold; wherein the dental mold has a second alignment feature positioned on a back end of the dental mold, opposite to the first alignment feature. wherein the first raised block feature has a shape complementary to the shape of the first alignment feature; wherein the second raised block feature has a shape complementary to the shape of the second alignment feature; andwherein contact of the first and second alignment features with the first and second raised block features, respectively, inhibits rotation and translational movement of the dental model.

10. The thermoform plate of claim 9, wherein the first raised block feature and or the second raised block feature includes a contoured surface configured to engage with a corresponding contoured surface of the dental model.

11. The thermoform plate of claim 1, wherein the locking system comprises: a first raised block feature extending from the top surface of the thermoform plate; one or more spring elements coupled to the top surface of the thermoform plate; wherein the dental model is positioned between the first raised block feature and the one or more spring element, and wherein the one or more spring elements contact the dental model and pushes the dental model against the first raised block feature.

12. The thermoform plate of claim 1, wherein the locking system comprises a raised block feature extending from the top surface of the thermoform plate and configured to abut the dental model when the locating feature interfaces with the locating socket; wherein the raised block feature is dimensioned to define a groove within a thermoformed film, the groove having an interior geometry designed to receive a separator support and one or more separator rods and provide access to one or more separator channels formed within the dental model.

13. A system comprising: a dental model of a patient’s dentition, the dental model comprising: one or more separator channels formed within the dental model, and a locating socket formed within a bottom portion of the dental model; a thermoform plate to secure the dental model during thermoforming, the thermoform plate comprising: a top surface for receiving a dental model; a locating feature extending from the top surface and configured to interface with the locating socket; anda raised block feature extending from the top surface of the thermoform plate and configured to abut the dental model when the locating feature interfaces with the locating socket; and a separator system to remove the dental model from a thermoformed film, the separator system comprising: a separator plate; and one or more separator rods coupled to the separator plate, configured to fit within the one or more separator channels formed within the dental model.

14. The system of claim 13, wherein the locking system comprises a spring element that interfaces with the dental model and applies force to the dental model, pushing the dental model against the raised block feature.

15. The system of claim 13, wherein the raised block feature includes flared portions configured to engage with facets of the dental model when the dental model is pressed against the raised block feature by the spring element.

16. The system of claim 13, wherein the raised block feature is dimensioned to define a groove within a thermoformed film, the groove having an interior geometry designed to receive one or more separator rods and provide access to the one or more separator channels formed within the dental model.

17. The system of claim 13, wherein the raised block feature further defines an internal cavity, wherein the internal cavity is dimensioned to receive a support positioned on the separator plate, wherein the one or more separator rods are connected to the support.

18. The system of claim 13, wherein: during use, an orthodontic aligner precursor is formed on the dental model and the thermoform plate, the orthodontic aligner precursor comprising an orthodontic aligner and excess thermoformed polymer at least partially surrounding the orthodontic aligner; where at least a portion of the excess thermoformed polymer extends over a portion of the separator plate when the one or more separator rods are placed within the separator channels of the dental model, during use; andwherein the separator system further comprises a clamp ring and a clamp platform, wherein, during use, the clamp ring and clamp platform contact the excess thermoformed polymer to secure the excess thermoformed polymer within the clamping system, and wherein the separator plate can be moved and / or tilted with respect to the clamp platform to separate the dental model from the thermoformed film without contacting the thermoformed aligner.

19. The system of claim 17, wherein the separator plate can tilt at an angle between about 0°-20°, 0°-15°, 0°-10°, or 0°-5° with respect to an upper surface of the clamp platform.

20. The system of claim 17, wherein the clamp ring includes a closed lid that forms a sealed separation chamber above the thermoformed film when the clamp ring contacts the clamp platform.

21. The system of claim 20, wherein the sealed separation chamber can be depressurized during separation of the dental model from the thermoformed film.

22. The system of claim 13, wherein the separator system is configured such that the separator system does not impart any fingerprint or feature onto thermoformed polymer formed on the dental model during use.

23. A separation system for separating a dental model from a thermoformed film, the separation system comprising: a separator plate comprising one or more separator rods, wherein the one or more separator rods are configured to fit within one or more separator channels formed within a portion of the dental model.

24. The separation system of claim 23, further comprising: a clamp platform; and a clamp ring, wherein a portion of the thermoformed film is fixed in place between the clamp platform and the clamp ring, and the separator plate is movable and / or tiltable with respect to the clamp platform, wherein the separator plate is movable and / or tiltable with respect to the clamp platform.

25. The separation system of claim 23, wherein the separator plate can tilt at an angle between about 0°-20°, 0°-15°, 0°-10°, or 0°-5° with respect to an upper surface of the clamp platform.

26. The separation system of claim 23, wherein the clamp ring includes a closed lid that forms a sealed separation chamber above the thermoformed film when the clamp ring holds the thermoformed film onto the clamp platform.

27. The separation system of claim 26, wherein the sealed separation chamber can be depressurized during separation of the dental model from the thermoformed film.

28. A method for thermoforming an orthodontic aligner, the method comprising: obtaining a molding device, the molding device comprising: a thermoform plate for receiving and securing individually unique dental models, the thermoform plate comprising: a locating feature extending from a top surface of the thermoform plate; and a locking system that secures the dental model to the locating feature during use; and a dental model positioned on the thermoform plate, wherein the dental model is a positive model of a dental arch, and wherein the dental model comprises a locating socket having a shape complementary to the locating feature, and wherein the dental model comprises one or more separator channels formed within the dental model; wherein the dental model is positioned on the thermoforming plate such that the locating socket mates with the locating feature when assembled; and thermoforming a polymer sheet over the over the molding device to form an orthodontic aligner precursor, on the dental model, wherein the orthodontic aligner precursor comprises the orthodontic aligner and excess thermoformed polymer at least partially surrounding the orthodontic aligner; coupling the dental mold to a separation system, wherein the separation system comprises a separator plate comprising one or more separator rods, and whereincoupling the dental mold to the separation system comprises positioning one or more separator rods within the one or more separator channels formed within the dental model; separating the orthodontic aligner precursor from the dental model.

29. The method of claim 28, wherein the separation system further comprises a clamp platform and a clamp ring, wherein a portion of the excess thermoformed polymer is fixed in place between the clamp platform and the clamp ring.

30. The method of claim 29, further comprising applying a vacuum within a chamber formed when the clamp ring contacts the clamp platform, wherein the excess thermoformed polymer is fixed in place to the clamp ring by the application of the vacuum.

31. The method of claim 29, wherein the separation plate is movable away from the clamp platform to separate the orthodontic aligner precursor from the dental model.

32. The method of claim 29, wherein the separation plate is movable in a linear direction away from the clamp platform.

33. The method of claim 29, wherein the separation plate can tilt with respect to the clamp platform.

34. The method of claim 28, further comprising cutting off the excess thermoformed polymer to produce the orthodontic aligner from the orthodontic aligner precursor.

35. A method for thermoforming an orthodontic aligner, the method comprising: obtaining a molding device, the molding device comprising: a thermoform plate for receiving and securing individually unique dental models, the thermoform plate comprising: a locating feature extending from a top surface of the thermoform plate; a locking system that secures the dental model to the locating feature during use; and one or more separator rods coupled to the thermoform plate a dental model positioned on the thermoform plate, wherein the dental model is a positive model of a dental arch, and wherein the dental model comprises alocating socket having a shape complementary to the locating feature, and wherein the dental model comprises one or more separator channels formed within the dental model; wherein the dental model is positioned on the thermoforming plate such that the locating socket mates with the locating feature when assembled; and wherein the dental model is positioned on the thermoforming plate such that the one or more separator rods are positioned within the one or more separator channels; thermoforming a polymer sheet over the over the molding device to form an orthodontic aligner precursor, on the dental model, wherein the orthodontic aligner precursor comprises the orthodontic aligner and excess thermoformed polymer at least partially surrounding the orthodontic aligner; coupling the thermoform plate to a clamping system, wherein the clamping system comprises a clamp platform and a clamp ring, wherein a portion of the excess thermoformed polymer is fixed in place between the clamp platform and the clamp ring; separating the orthodontic aligner precursor from the dental model be moving the thermoform plate away from the clamp platform.

36. The method of claim 35, further comprising applying a vacuum within a chamber when the clamp ring contacts the clamp platform, wherein the excess thermoformed polymer is fixed in place to the clamp ring by the application of the vacuum.

37. The method of claim 35, wherein the thermoform plate is movable in a linear direction away from the clamp platform.

38. The method of claim 35, wherein the thermoform plate can tilt with respect to the platform.

39. The method of claim 35, further comprising cutting off the excess thermoformed polymer to produce the orthodontic aligner from the orthodontic aligner precursor.