System and method for locating and verifying the anatomical position of a full-arch restoration

Abstract

A dental restoration positioning assembly includes an occlusal assembly and a maxillary dental arch subassembly. The occlusal assembly includes a maxillary support configured to be formed in a patient's maxillary alveolar ridge, wherein the maxillary support includes an occlusal ridge component. The occlusal assembly also includes a bracket frame component composed of a biocompatible magnetic metal material, which is anchored to the maxillary support. The maxillary dental arch subassembly includes a plurality of restorative maxillary dental components magnetically anchored to the occlusal ridge component. The bracket frame component is movable relative to the maxillary support. The plurality of restorative maxillary dental components are individually movable relative to each other to achieve desired tooth positioning.

Description

[0001] CROSS REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 931,999, filed on November 7, 2019, the entire contents of which are incorporated herein. Technical Field

[0003] The present disclosure generally relates to locating and verifying the anatomical position of a full-arch restoration. For example, the techniques described herein can be used to design and fit an implant or tissue-supported denture to a patient. Background Art

[0004] Restoration of the edentulous patient is a time-consuming and complex process that involves the dentist providing a patient-specific setup template to a dental laboratory technician to design a denture that meets the patient's functional and aesthetic requirements, including speech requirements. The traditional setup template (called a "wax rim," "bite rim," or "bite block") is a piece of wax that is adjusted and marked to capture patient-specific denture design considerations. The information captured by the setup template is essential for designing a tooth replacement restoration that can restore proper function of the masticatory system, speech, and smile aesthetics. The three-dimensional information required to rehabilitate the edentulous patient includes the occlusal plane; midline; incisal edge position; buccal channel; vertical distance; lip support and lip dynamics (high and low smile lines); and canine position ("3D parameters"). However, the traditional wax circle can only provide a subset of the 3D parameters. It does not capture the occlusal plane, buccal channel, and sometimes even the vertical distance. It also does not help evaluate function and speech.

[0005] In the traditional method of designing custom dentures, the dentist places the prefabricated denture teeth one by one into the wax circle by hand. As each tooth is placed, the dentist checks how well the upper teeth match the 3D parameters mentioned above and makes adjustments accordingly. This is a highly skilled and time-consuming process. Once all the denture teeth are placed in wax and designed, the "wax-up" is shipped to the dental laboratory for positioning of the back teeth and processing of the wax test teeth. The wax test teeth are then returned to the dentist. The dentist then places the wax-up in the patient's mouth and verifies that the 3D parameters are satisfactory.

[0006] If the wax-up needs adjustment, the dentist either makes the desired changes chairside or documents the changes through a combination of photographs, videos, and written descriptions. The wax-up is then shipped back to the dental technician with the desired changes. The technician adjusts the wax-up, and the revised wax-up is then shipped back to the dentist to evaluate the changes for the patient. This process is repeated until the wax-up is acceptable to both the dentist and the patient, and may take many sessions to perfect. Summary of the invention

[0007] Embodiments of the present invention address and overcome one or more of the above-mentioned shortcomings and deficiencies by providing methods, systems and apparatus associated with locating and verifying the anatomical positions of all individual teeth in a full-arch restoration.

[0008] According to some embodiments, a dental restoration positioning assembly includes an occlusal assembly and a maxillary dental arch subassembly. The occlusal assembly includes a maxillary support configured to be formed in a patient's maxillary alveolar ridge, wherein the maxillary support includes an occlusal ridge component. The occlusal assembly also includes a bracket frame component composed of a biocompatible magnetic metal material, which is anchored to the maxillary support. The maxillary dental arch subassembly includes a plurality of restorative maxillary dental components magnetically anchored to the occlusal ridge component. The bracket frame component is movable relative to the maxillary support. The plurality of restorative maxillary dental components are individually movable relative to each other to achieve desired tooth positioning.

[0009] According to another aspect of the present invention, in some embodiments, a method of manufacturing a dental restoration includes assembling a maxillary dental arch subassembly and a bite assembly into a patient's mouth. The maxillary dental arch subassembly and the bite assembly each include a plurality of movable components. The method also includes adjusting one or more of the patient's midline, incisal position, lip support, and buccal channel by repositioning one or more of the movable components. The final positions of the maxillary dental arch subassembly and the bite assembly are fixed to a dental restoration positioning assembly template to manufacture the dental restoration.

[0010] According to another aspect of the present invention, in some embodiments, a method for manufacturing a denture based on a template includes receiving one or more digital grids through a computer-aided design (CAD) system, wherein the digital grids depict a dental restoration positioning component template including a plurality of template maxillary dental arch teeth. A tooth and dental arch anatomical structure library corresponding to the maxillary dental arch teeth is identified in the dental restoration positioning component template. The tooth and dental arch anatomical structure library includes a plurality of library tooth models. A plurality of maxillary dental arch teeth from the tooth and dental arch anatomical structure library are aligned (automatically or manually) with the plurality of template maxillary dental arch teeth. Based on predetermined occlusal parameters applied to the plurality of maxillary dental arch teeth, a plurality of mandibular dental arch teeth from the tooth and dental arch anatomical structure library are automatically positioned. Based on the positioning of the plurality of maxillary dental arch teeth and the plurality of mandibular dental arch teeth, a gingival anatomical structure is automatically positioned. A digital model of a denture is generated based on the plurality of maxillary dental arch teeth, the plurality of mandibular dental arch teeth, and the gingival anatomical structure.

[0011] The following embodiments described with reference to the accompanying drawings will highlight additional features and advantages of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The foregoing and other aspects of the present invention may be best understood by reading the following detailed description in conjunction with the accompanying drawings. For the purpose of illustrating the present invention, presently preferred embodiments are shown in the accompanying drawings, however, it should be understood that the present invention is not limited to the specific embodiments disclosed. The drawings include:

[0013] Figure 1A A facial view of the square-toothed prosthesis positioning component is provided;

[0014] Figure 1B Shows Figure 1A Lingual view of the prosthesis positioning assembly shown;

[0015] Figure 1C Provides detailed views of components used in a prosthesis positioning assembly according to some embodiments;

[0016] Figure 2A The parts of the restoration positioning assembly are shown machined into a custom tray, i.e., a prefabricated U-shaped piece incorporating magnets;

[0017] Figure 2B A bracket frame is shown held by magnets incorporated into a lower customization bracket, wherein the bracket frame can be moved to customize the template to the patient's unique anatomy;

[0018] Figure 2C-2E The maxillary dental arch assembly is shown to include the anterior segment and the left and right posterior quadrants, connected to the custom-made maxillary tray via magnets;

[0019] Figure 3A and Figure 3B shows examples of different tooth shapes available in the shape library;

[0020] Figure 4A and Figure 4B provides further details of how magnets are retained and positioned in a prefabricated U-shaped member according to some embodiments;

[0021] Figure 5A and Figure 5B A side view and an occlusal view are provided, respectively, of a bracket frame according to some embodiments;

[0022] Fig. 6A and Figure 6B It is described how to use spacers to adjust the distance between the bracket frame and the custom maxillary tray, wherein the spacers are either magnets or magnetically retained;

[0023] Fig. 7A and Figure 7B Two different views of the anterior component of the maxillary dental arch assembly are shown;

[0024] Figure 7Cshows how the anterior maxillary component is connected to the bracket frame in a manner that allows the position of the anterior maxillary component to be adjusted;

[0025] Figure 8A-8C Three views of the right posterior component of the maxilla are shown;

[0026] Fig.9A An exemplary magnetic anchor on the anterior maxillary component for connecting the posterior quadrant to the bracket framework is shown;

[0027] Fig. 9B The magnetic anchors on the right posterior component of the maxilla are shown;

[0028] Figure 10A-10C providing three views of a mandibular anterior component according to some embodiments;

[0029] Fig.11A and Fig. 11B shows how a VDO nail is connected to a mandibular anterior component according to some embodiments;

[0030] Figures 12A-12D shows the process of connecting a mandibular anterior component to a maxillary anterior component by using a spacer;

[0031] Fig.13 A flow chart of the operational sequence of template customization according to some embodiments is provided; and

[0032] Fig.14 A method according to some embodiments is provided which describes how a validated Unity template becomes a temporary trial denture.

[0033] Detailed description

[0034] The present invention is described below according to several embodiments, which relate to methods, systems and devices related to the use of a restoration positioning assembly to locate and verify the anatomical position of a full-arch dental restoration. The restoration positioning assembly helps clinicians locate and verify 3D parameters, functions and voices. As described in further detail below, the restoration positioning assembly can be provided to clinicians as a collection of standardized parts that are intended to be used by clinicians as templates to locate and verify the anatomical position of a full-arch restoration. This collection is referred to herein as the "Unity Kit". In order to cover the breadth of anatomical oral sizes and shapes, the kit can be divided into multiple template selections. For example, in some embodiments, 3 dental arch sizes and 5 tooth shapes are provided. The combination of these dental arch sizes and tooth shapes, as well as the dynamic positioning device described below, enables clinicians to create templates for the final restorations of various patients.

[0035] The creation of a full-arch restoration using the Unity system is performed in a series of discrete steps. First, the clinician uses the Unity kit template (described above) to find the correct 3D position of the restoration as well as the arch and tooth shapes at chairside. After verifying all 3D parameters, the 3D position of the Unity kit template in the mouth represents a "patient-specific" template (called a "custom template," "template," or "wax-up") that is unique to that patient. In this case, "chairside" means in the clinician's office while the clinician examines the patient. Next, the customized Unity template is digitized using an optical scanner and used as a template to design the restoration using dental computer-aided design ("CAD") software. All simulated tooth shapes and dimensions in the dental arch are displayed in a digital anatomical library located in CAD to quickly design the prosthetic device. This design can be used to realize a variety of different prosthetic devices, including temporary soft tissue-supported dentures, implant-supported temporary dentures, surgical guides for implant placement, or alternative restorations.

[0036] Figure 1A A facial view of a square tooth shape restoration positioning assembly 100 is provided. As described in further detail below, various tooth shapes may be used as needed to match the patient's desire for the size and shape of the teeth in the final restoration. Figure 1B Shows Figure 1A The lingual side view of the prosthesis positioning assembly 100 is shown. Figure 1A and Figure 1B As shown, the prosthesis positioning assembly 100 is composed of two subassemblies: a maxillary dental arch subassembly 101 and a mandibular anterior portion and VDO pin assembly 102 .

[0037] Figure 1C A detailed view of components used in a prosthesis positioning assembly 100 is provided according to some embodiments. Figure 1C The images shown in the figure are relative to the human anatomy and Figure 1A and Figure 1B The orientation presented in FIG. 1 is "inverted". The maxillary arch subassembly 101 includes a maxillary arch left rear component 105, a maxillary arch front component 115, and a maxillary arch right rear component 120. These three components work together in the oral cavity to: determine the incisal edge position, midline position, occlusal plane, buccal channel, and lip support.

[0038] The bite assembly 110 secures the maxillary dental arch subassembly 101 in place. As explained in further detail below, the bite assembly 110 is designed so that the components 105, 115 and 120 of the maxillary dental arch subassembly 101 are removable after being mounted to the bite assembly 110. This allows the clinician to adjust the components 105, 115 and 120 to achieve the desired positioning of the maxillary dental arch subassembly 101. Once these components 105, 115 and 120 are placed, the mandibular anterior and VDO nail assembly 102 can be placed to assess the overall tooth positioning. The mandibular anterior and VDO nail assembly 102 includes a mandibular anterior component 125 and a VDO nail 130. The VDO nail 130 allows the vertical distance of occlusion ("VDO") to be adjusted to achieve the desired 3D positional relationship (i.e., vertical distance) between the maxilla and mandible.

[0039] Figure 2A and Figure 2B The figure shows how the prosthesis positioning assembly 100 can be used with the bite assembly to customize a template that fits the patient's unique anatomy. The bite assembly includes a maxillary support 200 and a support frame component 210 (respectively at Figure 2A and Figure 2B ). The two parts are designed to serve as an adjustable base for the restoration positioning assembly 100, allowing the clinician to quickly and dynamically adjust the position of the occlusal plane. The occlusal plane is an important restorative variable for full arch reconstruction because it determines the upper / lower components of the incisal edge position. The occlusal assembly provided in the Unity kit is available in a variety of sizes (e.g., small, medium, large, etc.) to allow customization to the size of the patient's mouth.

[0040] The maxillary support 200 is intended to form the soft tissue structure of the patient's upper jaw. Figure 2A As shown, maxillary support 200 includes moldable material 201 and occlusal dam component 205. Moldable material 201 can be formed in the patient's mouth, or formed on a stone model of the patient's maxilla before the patient's visit. Figure 2B It is shown how the bracket frame member 210 is anchored to the maxillary bracket 200. As explained in further detail below, in some embodiments, the bracket frame member 210 is made of a ferromagnetic material and the occlusal dam member 205 includes a plurality of magnets.

[0041] Figure 2C-2E 1 shows how the maxillary arch subassembly is connected to the bite assembly 110. Figure 2C As shown, the maxillary anterior component 215 is anchored to the bracket frame component 210. Next, as shown in FIG. Figure 2D As shown, the maxillary left rear component 220 is anchored to the maxillary front component 215. Then, the maxillary dental arch subassembly component 225 is anchored to the Figure 2E It should be noted that the order of the components of the maxillary dental arch subassembly may vary in different embodiments. Figure 2C-2E The order shown in is merely exemplary. For example, magnetic gaskets embedded in one or more of the maxillary anterior component 215, the maxillary left posterior component 220, and the maxillary dental arch subassembly component 225 may be used to achieve anchoring between the various components.

[0042] As is generally understood by those skilled in the art, the shape and position of the maxillary alveolar ridge varies depending on each patient's unique anatomy and length of time without teeth (known as "edentulism"). The width of the maxillary alveolar ridge, also known as the "ridge size," is accommodated by the multiple different sized bite components in the Unity kit. The size of the bite component (small, medium, large, etc.) will correspond to the size of the maxillary dental arch component. Once the bite component size is selected, the tooth shape can be selected.

[0043] A person's maxillary teeth vary in size and shape. Facial structure, arch size, and personal patient preferences need to be considered. In addition, a patient may have a personal preference for the appearance of his or her teeth. In some embodiments, the Unity kit provides different tooth shapes for each ridge size. For example, for each ridge size, tooth shapes with oval, square, and round morphologies can be provided. For example, the various shapes can be determined from a natural tooth model. During the patient evaluation phase, the tooth shapes can be quickly installed or detached from the bracket frame 505 chairside. In addition, these tooth shapes are designed with adjustable rear components 220 and 225, which function to match the patient's buccal channels. To illustrate, Figure 3A and Figure 3B Example square and round tooth shapes are shown respectively.

[0044] The ideal position of a person's maxillary teeth relative to the rest of the mouth varies based on many physiological characteristics, including but not limited to facial structure, lip dynamics, skeletal anatomy, and speech. By combining the occlusal component and the prosthesis positioning component, the clinician is able to quickly position the dental arch in the correct physiological position by adjusting the occlusal plane position, incisal edge position, midline, buccal channel, lip support, and VDO. The clinician is then able to physiologically verify the position in the mouth through speech and lip dynamics and then adjust the position accordingly. This allows the clinician to create a validated template for the final restoration in a single chairside appointment.

[0045] Figure 4A and Figure 4B Further details of the occlusal dam component 205 according to some embodiments are provided. The maxillary support 400 is composed of a rigid occlusal dam 405 surrounded by a moldable material. The occlusal dam 405 is designed to the shape of a natural dental arch. The occlusal dam 405 includes a plurality of embedded magnetic anchors. Figure 4AIn the example shown, the anchors include magnetic anchors 410A, 410B, 410C, and 410D (i.e., two anchors at the rear and two anchors at the front). The magnetic anchors 410A, 410B, 410C, and 410D, when assembled to the edge of the occlusal ridge 405, attach the ferromagnetic bracket frame (see, e.g., Figure 2B ) is attracted to the mating position. The moldable material can be formed around the bite ridge, for example, by injection molding. Figure 4B As shown, the occlusal ridge 405 includes a plurality of undercuts 415A, 415B, 415C, and 415D for overmolding material. The moldable material is used to secure the magnetic anchors 410A, 410B, 410C, and 410D into the occlusal ridge 405 and conform to the unique contours of the patient's maxillary alveolar ridge, serving as a customized final impression and registration base.

[0046] Figure 5A and Figure 5B A side view and an occlusal view of a bracket frame 505 according to some embodiments are provided, respectively. The bracket frame 505 is constructed of a biocompatible magnetic metal material. The shape of the bracket frame 505 reflects the natural dental arch shape of the occlusal ridge 405, except for the anterior lingual region, where the shape may be thinner. The bracket frame 505 is designed to align with the magnetic anchor of the maxillary bracket along a range of linear positions (see Figure 4A ) overlap. This allows the bracket frame 505 to be adjusted and fixed in any position, depending on the strength and position of the magnetic anchor. For example, for the above Figure 4A and 4B In the maxillary support 400 shown, the anchors can allow for adjustment up to 6 mm in the anterior direction. This feature allows for "macro adjustment" of the anterior / posterior components of the incisal edge position. Fine adjustments can be made by adjusting the various components of the restoration positioning assembly.

[0047] Fig. 6A and Figure 6B The use of spacers 615A, 615B, 615C, and 615D to adjust the distance between the bracket frame 605 and the maxillary support 600 is illustrated. In this example, the spacers 615A, 615B, 615C, and 615D are magnetically attracted to anchors in the occlusal ridge 610, which serves to position the spacers in the correct position. By adding or removing spacers, the bracket frame 605 can be adjusted up and down (superior / inferior) relative to the maxillary support 600. In addition, the bracket frame 605 can be angled by adding additional spacers to the anterior anchors, such as Figure 6B By adjusting the size of the spacers individually, any angle of the bracket frame 605 can be achieved. The angle of the bracket frame 605 becomes the restoration occlusal plane. Fig. 6A and Figure 6BThe example of the embodiment utilizes magnets as spacers, but it should be understood that other types of spacers can be used in other embodiments. For example, in one embodiment, the spacers are stackable plastic spacers that "snap" onto each other to achieve the desired height. The plastic spacers can also include features that allow interlocking with the bracket frame 605 and the snap dam 610.

[0048] Figure 7A-7C Additional details regarding the maxillary dental arch subassembly according to some embodiments are provided. Fig. 7A and Figure 7B , two different views of the maxillary front component 700 are shown. The maxillary front component 700 includes the facial and occlusal contours of the six maxillary front teeth, and a crescent-shaped protrusion 705 from the lingual side of the teeth. The crescent-shaped protrusion 705 includes spaces for accommodating magnets 710A, 710B, 710C, and 710D (or other connectors) of various sizes. Figure 7C It is shown how the maxillary anterior component 700 is magnetically connected to the bracket frame 715 in a manner that allows the position of the maxillary anterior component 700 to be adjusted.

[0049] Figure 8A-8C Three views of the maxillary left posterior component 800 are shown. Fig. 8A The occlusal and buccal views are shown, and Figure 8B and 8C The lingual and top views are shown, respectively. The maxillary right posterior and maxillary left posterior are mirror images of each other. The maxillary right posterior component and the maxillary left posterior component each contain the buccal and occlusal profiles of the 4 posterior teeth. The lingual side of the component includes a flat surface, a rounded surface, and space for various sized magnets 805 and 810 (or other connectors).

[0050] In some embodiments, the maxillary right posterior component and the maxillary left posterior component are connected to the maxillary anterior component using a combination of magnetic anchor components located on the lingual side of the first bicuspid on all three parts. The anchors allow the components to be rotated along the occlusal plane. This design feature allows the left and right posterior buccal channels to be adjusted while preserving the occlusal plane. The magnetic anchors can also be designed to limit rotation to a desired range of the baseline arch (e.g., + / - 10 degrees). Fig.9A Exemplary magnetic anchors 905, 910 are shown on the maxillary anterior component 900 for connecting the posterior component. Fig. 9B A magnet anchor 920 is shown on the maxillary left posterior component 915. The maxillary right posterior anchor (not shown) is a mirror image of the maxillary left posterior anchor 920.

[0051] The maxillary arch subassembly is designed to magnetically anchor to the bracket frame portion of the bite assembly, which serves as a base. The anchors that connect the posterior portion can be repurposed to securely attract the maxillary arch subassembly to the bracket frame in a manner that limits movement. Therefore, the maxillary arch subassembly can only be adjusted within the occlusal plane set by the bite assembly. The maxillary arch subassembly can be moved to a unique midline position and adjusted anteriorly to ideal incisal edge position and lip support position.

[0052] Figure 10A-10C Three views of a mandibular anterior component 1000 according to some embodiments are provided. In this example, the mandibular anterior component 1000 is designed with the lower six anterior teeth. Fig. 10B and 10C As shown, the mandibular anterior component 1000 includes a hole 1005 for receiving a VDO peg.

[0053] Fig.11A and Fig. 11B 100. The VDO nail 1105 is connected to the concave surface (tissue side) of the mandibular anterior component 1100 according to some embodiments. The VDO nail 1105 is connected to the concave surface (tissue side) of the mandibular anterior component 1100. The VDO nail 1105 enables the clinician to adjust the VDO, which is a key repair variable in full arch reconstruction. More specifically, the VDO nail 1105 is designed to be shortened by the clinician chairside (e.g., using a dental handpiece) to achieve the correct VDO. In some embodiments, the VDO nail 1105 has markings at predetermined intervals (e.g., 1 mm) indicating the distance from the occlusal plane.

[0054] In some embodiments, the mandibular anterior component is connected to the maxillary anterior component using a magnetic spacer and corresponding magnetic anchors embedded in both components. The anchors are located on the lingual side of the maxillary and mandibular canines and are used to limit all movement of the mandibular anterior component relative to the maxillary anterior component. The function of the spacer is to connect the mandibular anterior component to the maxillary anterior component, maintain the occlusal distance between the two components when they are mated, and represent the positioning of the entire lower dental arch as it relates to the teeth of the upper dental arch in an ideal occlusal relationship.

[0055] Figures 12A-12D The mandibular anterior component 1215 is shown connected to the maxillary anterior component 900 (referenced above). Fig.9A and Fig. 9B By inserting the anchor 95 into Fig. 12A The maxillary anterior component 900 is connected to the mandibular anterior component 1215 in the space 1220 shown. Fig. 12B The mandibular anterior component 1215 and spacers 1225A and 1225B are shown. Fig. 12C Buccal and lingual views of the spacers 1225A and 1225B on the mandibular anterior component 1215 are shown. Finally, Fig.12D The positions of the anchors 905 and 910 are shown when the mandibular anterior component 1215 and the maxillary anterior component 900 are anchored together.

[0056] Fig.13 A flow chart of the operational sequence of template customization according to some embodiments is provided. Starting from step 1305, the customized patient-specific base is inserted into the patient's mouth and its retention and stability are evaluated. The Unity kit can provide multiple base plates of different sizes. In step 1310, the clinician selects the tooth shape and arch size suitable for the patient's specific situation and preferences from the library. In addition, the clinician assembles the bracket framework and the maxillary dental arch components. Next, in step 1315, the clinician adds the spacer to the bite component as needed to achieve the correct occlusal plane and incisal position. In step 1320, the clinician can also move the bracket framework forward or backward when necessary, and can move the dental arch component forward or backward and left and right relative to the bracket framework to establish the midline, lip support and buccal channel. Then, in step 1325, all parameters are now set, and the clinician verifies the maxillary dental arch position by asking the patient to say the sound "F" and / or "V". If necessary, the clinician will adjust the position of the maxillary dental arch.

[0057] Continue to refer Fig.13 , at step 1330, the mandibular anterior and VDO pins (if necessary) are added. If necessary, the clinician adjusts the VDO. For example, in some embodiments, the VDO is calculated by subtracting the "freeway space" from the rest vertical distance ("VDR"). As generally understood in the art, when the mandible is in a rest position, there is a gap between the upper and lower teeth. The occlusal space observed in the premolar area is the "freeway space". In other embodiments, the denture is designed for replacement purposes and the VDO can be matched to the VDO of the existing denture. The positioning of the VDO may also be affected by the patient's facial aesthetics. At step 1335, the clinician fixes the position of the maxillary arch subassembly relative to the maxillary support, and the position of the mandibular anterior component relative to the mandibular support using, for example, a flowable, curable material.

[0058] At step 1340, once the maxillary and mandibular components have been secured to the maxillary and mandibular supports, the clinician can remove the spacer to separate the maxillary component from the mandibular component. The maxillary and mandibular bones are now free to move independently of each other. The lower anterior teeth are now secured in the correct position, and the clinician then has the patient make a sound "S" to verify the VDO, upper and lower incisal edge positions. The clinician then has the patient smile to confirm tooth size and selection at step 1345. If a change in arch shape, tooth shape, or intra-oral position is required, process 1300 can be restarted. Once the desired appearance and fit is achieved, at step 1350, the clinician can capture the position of the maxillary and mandibular components using a chairside scanner, or the entire assembly can be connected and shipped to a laboratory for manufacturing.

[0059] Fig.14 A method 1400 is provided according to some embodiments, which describes how a verified Unity template becomes a temporary trial denture. Beginning at step 1403, the customized Unity template is converted into a digital mesh with an optical 3D scanner. At step 1405, multiple digital meshes are uploaded to a computer-aided design (CAD) software system. Example CAD software systems include 3Shape Dental System, Exocad DentalCAD, and AvaDent Digital Denture. The digital meshes include maxillary and mandibular soft tissue digital meshes that can provide detailed details of the soft tissue model, including the denture boundaries. At step 1405, a digital mesh of the entire Unity template is uploaded, including a digital mesh of the occlusal component, a maxillary dental arch subcomponent, and a mandibular support fixed together. Together, these digital meshes provide a VDO for the CAD software. At step 1405, the uploaded digital mesh also includes a digital mesh of the occlusal component with the maxillary dental arch subcomponent to provide a relationship between the maxillary soft tissue and the verified tooth positions.

[0060] Continue to refer Fig.14 , in steps 1410-1420, the model is ready for design. First, in step 1410, the user selects the type of denture structure they wish to manufacture (e.g., 1pc, 2pc, printed, milled, hybrid, etc.). Next, in step 1415, the CAD software system aligns the grid, trims, and corrects digital mesh defects as needed. Then in step 1420, the CAD software system performs model analysis, including occlusal planes and feature points, marking jaw boundaries, setting insertion directions, and closing undercuts. The processing of steps 1415 and 1420 can be performed automatically or based on one or more inputs received from the user.

[0061] In steps 1425-1435, the user uses the information provided by the CAD software system to design a full-mouth restoration trial denture based on the input. In step 1425, the user selects the corresponding tooth shape and arch size represented by the simulation setup from the anatomical structure library. The arch shape is manually or automatically positioned relative to the custom template, and the teeth are adjusted individually. Next, in step 1430, the denture base (representing the tissue) is created. The denture base can be generated in different configurations to create a denture (full palatal base coverage) or an implant-supported restoration (covering the arch base only). In step 1435, the micro-anatomy is adjusted using digital sculpting tools along with the denture base component parameters. At this point, the design of the trial denture can be finalized and used to manufacture the denture.

[0062] Once the position of the dentition has been digitized using the process described in steps 1405 through 1425, any full mouth dental restoration may be designed including, but not limited to, a denture, a radiographic guide, or an implant restoration. Fig.13 and Fig.14 The procedures described in represent the entire analog and digital workflow for achieving optimal full-mouth reconstruction.

[0063] In some embodiments, a trial denture is manufactured with a cavity along the lingual side of the maxillary denture base or dental arch. The cavity receives a radiopaque material (e.g., gutta-percha or zirconium oxide spheres). The trial denture with radiopaque markers is used in conjunction with cone beam computed tomography ("CBCT") to generate a data set that correlates the three-dimensional position of the trial denture relative to the patient's tissue and bone. This data set can then be compared to Fig.14 The data sets generated in the present invention are combined to generate, for example, (i) guidelines for surgical placement of one or more dental implants and (ii) a temporary implant restoration based on the planned implant positions.

[0064] After the simulated part is scanned and digitized in the CAD software, the corresponding dental arch shape in the anatomical structure library is selected. The differences in the dental arch shape geometry are determined, particularly the repositioning of the posterior quadrant, and the CAD software coordinates the posterior quadrant of the digital mesh with the new simulated position. In some embodiments, CAD recognizes that changes need to be made to adapt the CAD position to the simulated part. Then, as the CAD software adjusts the design, it ensures that the design retains key relationships, including the cusp fossa and general occlusal function. The positioning of the lower anterior teeth is representative of the positioning of the entire lower dental arch as it relates to the teeth in the upper dental arch in an ideal occlusal relationship.

[0065] Fig.14The software process described in the and described in more detail. Various enhancements to conventional software for designing and assembling implant or tissue-supported dentures are provided herein. For example, in some embodiments of the present invention, a mesh database corresponding to physical teeth, dental arches, and tissue anatomical structures is utilized. The anatomical structure library includes multiple teeth, dental arches, and tissue anatomical structures corresponding to multiple physical maxillary and mandibular dental arch anatomical structures in the restoration positioning assembly. The tooth, dental arch, and tissue anatomical structure mesh database contains additional anatomical structure metadata, such as free gingival margin lines, cusp and fossa locations, contours of interdental papillae and attached mucosa, contact point locations, etc.

[0066] The technology described herein facilitates the placement / alignment of maxillary teeth and dental arch shapes. Multiple dental anatomical structure meshes in the anatomical structure library are registered to the digital mesh of the customized Unity template using single or multiple user-marked reference points through a mesh alignment algorithm (e.g., iterative closest point). In some embodiments, multiple tooth meshes are arranged into 3 rigid groups corresponding to the maxillary anterior, maxillary left posterior, and maxillary right posterior components. Automatic mesh alignment of multiple teeth can quickly replicate verified tooth positions and dental arch shapes of a customized Unity template without requiring a lot of user input. Traditional software workspaces for tooth placement and alignment (e.g., 3Shape's Smile Composer function) require users to manually drag and rotate individual meshes or groups of tooth meshes to the desired 3D position using on-screen controls. The tooth mesh is positioned relative to the mesh of the wax embankment (not containing tooth references) or the mesh of the wax model (containing non-corresponding tooth references). Manual alignment is time-consuming and inaccurate.

[0067] The system described herein also facilitates the identification, positioning, and characterization of gingival tissue anatomy. The digital mesh representing the customized Unity template includes gingival tissue anatomy. The free gingival margin metadata packaged with the tooth mesh anatomy library can quickly identify buccal gingival tissue through a Boolean difference algorithm. Multiple registered tooth meshes are subtracted (by Boolean difference) from the digital mesh of the customized Unity template to obtain a mesh representing the tissue anatomy above the free gingival margin. Using a single or multiple user-marked reference points, the tissue mesh within the anatomy library is aligned to the tissue mesh remaining after subtraction by a mesh alignment algorithm (e.g., iterative closest point). The tissue mesh is then lofted to the denture boundary to generate a complete denture base. The automatic identification and positioning of pre-characterized tissues significantly reduces the skilled input required by the user and enables the tissue design to be modified when changes are required. Traditional dental CAD software workspaces for tissue design can dynamically generate tissue surfaces by: 1) by creating a lofted surface from the denture boundary to the free gingival margin of the denture library teeth or 2) lofting from the denture boundary to the upper boundary of the library teeth and tissue arch. Conventional algorithms used in Approaches 1 and 2 create non-aesthetic tissue designs that must be corrected digitally or manually after fabrication.

[0068] According to some embodiments, the systems described herein utilize a decorative design of a denture having a cavity along the lingual side of the dental arch. A 1-piece or 2-piece denture design having multiple cylindrical cavities is positioned along the lingual tissue surface of the denture arch. In other embodiments, the cylindrical cavities can be positioned along the tissue surface of the denture base or dental arch (referred to as a "gutter"). As described above, the cylindrical cavities can be incorporated into the denture during a CNC milling or 3D printing manufacturing process. A radiopaque material (e.g., zirconium oxide, metal, or gutta-percha) is placed into the cylindrical cavity after manufacturing.

[0069] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0070] The systems and processes of the accompanying drawings are not exclusive. Other systems, processes, and menus can be derived based on the principles of the present invention to achieve the same goals. Although the present invention has been described with reference to specific embodiments, it should be understood that the embodiments and variations shown and described herein are for illustrative purposes only. Those skilled in the art may modify the current design without departing from the scope of the present invention. Any claim element herein shall not be interpreted according to the provisions of 35 U.S.C. 112 (f) unless the element is explicitly referenced using the phrase "means".

Claims

1. A dental restoration positioning assembly, comprising: A bite assembly, the bite assembly comprising: a maxillary support configured to be formed in a maxillary alveolar ridge of a patient, wherein the maxillary support comprises an occlusal ridge component, and a bracket frame member composed of a biocompatible magnetic metal material, anchored to the maxillary bracket, a maxillary dental arch subassembly comprising a plurality of restorative maxillary dental components magnetically anchored to the occlusal ridge component, and one or more spacers for adjusting the distance between the bracket frame component and the maxillary support, the distance being adjusted by stacking or not stacking the spacers, wherein (i) the bracket frame component is movable relative to the maxillary bracket, and (ii) the plurality of restorative maxillary dental components are individually movable relative to each other to achieve desired tooth positioning.

2. The dental restoration positioning assembly according to claim 1, wherein the plurality of restoration maxillary dental components in the maxillary dental arch subassembly comprises: left posterior component of maxillary dental arch; maxillary anterior component; and Right posterior component of the maxillary dental arch.

3. The dental restoration positioning assembly according to claim 2, wherein the maxillary anterior component is movable along the bracket frame component in anterior and posterior directions to achieve a desired incisal edge position.

4. The dental restoration positioning assembly according to claim 2, wherein the plurality of restoration maxillary dental components are movable in the left-right direction along the bracket frame component to achieve a desired maxillary midline position of the patient's mouth.

5. The dental restoration positioning assembly according to claim 2, wherein the maxillary dental arch left rear component and the maxillary dental arch right rear component can be rotated independently on the bracket frame component relative to the maxillary front component to achieve a desired buccal channel of the patient's mouth.

6. The dental restoration positioning assembly according to claim 2, wherein the posterior maxillary dental components of the maxillary dental arch subassembly are connected to each other by magnetic anchors.

7. A dental restoration positioning assembly according to claim 6, wherein the magnetic anchor restricts all movement of the posterior maxillary dental component except rotation.

8. The dental restoration positioning assembly according to claim 2, wherein the maxillary front component comprises facial contours, occlusal contours and lingual contours of six maxillary front teeth.

9. The dental restoration positioning assembly according to claim 8, wherein the maxillary dental arch left rear component and the maxillary dental arch right rear component each include a buccal contour, an occlusal contour and a lingual contour of four posterior teeth.

10. The dental restoration positioning assembly according to claim 9, wherein the maxillary anterior component comprises a crescent-shaped protrusion, the crescent-shaped protrusion is located on the lingual side of the maxillary anterior teeth and has one or more anchors to connect with the maxillary dental arch left posterior component and the maxillary dental arch right posterior component.

11. The dental restoration positioning assembly according to claim 10, wherein the one or more anchors are magnets or ferromagnetic materials.

12. The dental restoration positioning assembly of claim 1, wherein the occlusal dam component comprises a plurality of embedded magnetic anchors and / or ferromagnetic material.

13. The dental restoration positioning assembly of claim 12, wherein the plurality of embedded magnetic anchors include (i) a first set of magnetic anchors located in front of the occlusal dam component and (ii) a second set of magnetic anchors located behind the occlusal dam component.

14. The dental restoration positioning assembly of claim 1, wherein the spacer is a magnetic washer anchored to the occlusal dam component.

15. The dental restoration positioning assembly of claim 1, wherein the spacer is arcuate and is magnetically anchored to the occlusal dam component.

16. The dental restoration positioning assembly according to claim 1, further comprising: A mandibular anterior subassembly having a plurality of restored mandibular teeth.

17. The dental restoration positioning assembly according to claim 16, wherein the mandibular front portion comprises a pin for adjusting the occlusal vertical distance, the 3D positional relationship between the patient's maxilla and the patient's mandible.

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