A semi-automatic forming and cutting method and system for fabricating double braces using a single diaphragm

Abstract

This invention relates to a semi-automatic molding and cutting method and system for fabricating double braces using a single diaphragm, belonging to the field of CNC machine tool technology. The method includes: printing an orthodontic model set to obtain an orthodontic model; hot-pressing the orthodontic model to obtain a brace model; positioning the orthodontic model set in the OrthCurve module to obtain cutting positioning keys and gingival cutting lines, resulting in a cutting model; a visual scanning module identifying the brace positioning keys and digital codes of the brace model, obtaining the cutting model associated with the digital codes, matching the cutting positioning keys in the cutting model with the brace positioning keys to obtain the cutting positioning keys and gingival cutting lines of the cutting model, generating a processing file, and then cutting the brace model to obtain the braces using a cutting machine. This method allows two orthodontic models to be placed on the molding jig at once, improving the capacity utilization and production efficiency of the molding machine, eliminating the requirement for precise model placement, and reducing placement errors caused by manual operation.

Description

Technical Field

[0001] This invention belongs to the field of CNC machine tool technology, specifically relating to a semi-automatic forming and cutting method and system for fabricating double dental braces using a single diaphragm. Background Technology

[0002] Currently, the general manufacturing process for invisible braces is as follows:

[0003] 1. Use a 3D printer to print the three-dimensional model data to obtain the model.

[0004] 2. Use a molding machine to thermo-press the dental diaphragm and the 3D printed model into shape.

[0005] 3. The braces are made by cutting them manually or by using CNC equipment to cut them out along the pre-set edge path.

[0006] The above method can only make one dental brace using a single dental film. Furthermore, the position of the dental brace model needs to be precisely controlled during the molding and cutting process, resulting in a high error rate and low production efficiency. The capacity of the molding and cutting machines is not being maximized. Summary of the Invention

[0007] To address the aforementioned problems in the prior art, in a first aspect, the present invention provides a semi-automatic forming and cutting method for fabricating double dental braces using a single diaphragm, comprising the following steps:

[0008] S1: Generate an orthodontic model group, print the orthodontic model group, and obtain an orthodontic model. The orthodontic model group includes a maxillary model group and a mandibular model group.

[0009] S2: The orthodontic model is hot-pressed to obtain a braces model, which includes braces positioning keys and digital codes;

[0010] S3: Import the orthodontic model group into the OrthCurve module, perform positioning processing on the orthodontic model group to obtain the cutting positioning key and gingival cutting line, export the processing results, and obtain the cutting model;

[0011] S4: The visual scanning module identifies the braces positioning keys and digital codes of the braces model, obtains the cutting model associated with the digital codes, matches the cutting positioning keys in the cutting model with the braces positioning keys, obtains the matching results, obtains the cutting positioning keys and gingival cutting lines associated with the cutting model, generates a processing file based on the matching results, the cutting positioning keys and the gingival cutting lines, inputs the processing file into the cutting machine, and the cutting machine cuts the braces model according to the processing file to obtain the braces.

[0012] Specifically, the hot pressing method in S2 is as follows:

[0013] Two orthodontic models are placed on a pressure mold tray. The maximum arch width of the orthodontic model is less than 75 mm, and the distance between the distal positions of the arches of the orthodontic models is greater than 10 mm and less than 25 mm. The orthodontic models are then thermoformed to obtain two braces models.

[0014] Specifically, the OrthCurve module in S3 mirrors the cutting model to obtain a mirrored cutting model, a mirrored cutting locator, and a mirrored gingival cutting line.

[0015] Specifically, the method for identifying the braces model in S4 is as follows:

[0016] The visual scanning module identifies the braces positioning keys and digital codes of two braces models, obtains the cutting model and mirror cutting model associated with the digital codes, and matches the cutting positioning keys in the cutting model and the mirror cutting positioning keys in the mirror cutting model with the braces models to obtain the matching results.

[0017] In a second aspect, the present invention also provides a semi-automatic molding and cutting system for fabricating double braces using a single diaphragm, which operates using the method described in any one of claims 1-4, characterized in that it includes a model generation module, a 3D printing module, a laminating machine, an OrthCurve module, a visual scanning module, and a cutting machine, wherein the model generation module generates the orthodontic model set;

[0018] The 3D printing module prints the orthodontic model set to obtain an orthodontic model.

[0019] The molding machine hot-presses the orthodontic model to obtain a braces model.

[0020] The OrthCurve module performs positioning processing on the orthodontic model group to obtain the cutting positioning key and gingival cutting line, thus obtaining the cutting model;

[0021] The visual scanning module identifies the braces positioning keys and digital codes of the braces model, obtains the cutting model associated with the digital codes, matches the cutting positioning keys in the cutting model with the braces positioning keys to obtain a matching result, obtains the cutting positioning keys and gingival cutting lines associated with the cutting model, and generates a processing file based on the matching result, the cutting positioning keys, and the gingival cutting lines.

[0022] The cutting machine cuts the dental brace model according to the processing file to obtain the dental brace.

[0023] The cutting machine and the film pressing machine have the same dimensions and the same positioning hole positions. The film pressing fixture plate of the film pressing machine is typically a circle with a diameter of 120mm or 125mm or a square with a side length of 127mm; in this invention, the film pressing fixture plate is a circle with a diameter of 133mm. The specifications of the film pressing fixture plate are consistent with those of the film sheet; when the specifications of the film pressing fixture plate change, the specifications of the film sheet change accordingly.

[0024] The beneficial effects of this invention are as follows:

[0025] (1) By using a 133mm pressing jig, two orthodontic models can be placed on the pressing jig at one time, which improves the capacity utilization and production efficiency of the pressing machine.

[0026] (2) By automatically copying the mirror model, it is possible to successfully complete the operation by randomly placing any numbered model from the same maxilla or mandible on the pressing jig plate, eliminating the requirement for model placement and reducing the model placement error caused by manual operation. Attached Figure Description

[0027] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0028] Figure 1 A schematic flowchart illustrating the semi-automatic forming and cutting method for fabricating double dental braces using a single diaphragm according to the present invention;

[0029] Figure 2 This is a structural block diagram of the semi-automatic forming and cutting method system for fabricating double braces using a single diaphragm, as described in this invention. Detailed Implementation

[0030] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0031] Please see Figure 1 A flowchart illustrating a semi-automatic forming and cutting method for fabricating double dental braces using a single diaphragm is provided, including the following steps:

[0032] S1: Generate an orthodontic model group, print the orthodontic model group, and obtain an orthodontic model. The orthodontic model group includes a maxillary model group and a mandibular model group.

[0033] S2: The orthodontic model is hot-pressed to obtain a braces model, which includes braces positioning keys and digital codes;

[0034] S3: Import the orthodontic model group into the OrthCurve module, perform positioning processing on the orthodontic model group to obtain the cutting positioning key and gingival cutting line, export the processing results, and obtain the cutting model;

[0035] S4: The visual scanning module identifies the braces positioning keys and digital codes of the braces model, obtains the cutting model associated with the digital codes, matches the cutting positioning keys in the cutting model with the braces positioning keys, obtains the matching results, obtains the cutting positioning keys and gingival cutting lines associated with the cutting model, generates a processing file based on the matching results, the cutting positioning keys and the gingival cutting lines, inputs the processing file into the cutting machine, and the cutting machine cuts the braces model according to the processing file to obtain the braces.

[0036] In this embodiment, the average complete treatment cycle for a patient with invisible braces is approximately 50 steps. The manufacturer produces 10 steps per shipment, resulting in 20 models per patient per batch. During software processing, each orthodontic model is renamed according to the rule "ID + maxillary / mandibular identifier + number of steps," where the maxillary / mandibular identifier includes U and D, with U representing the maxilla and D representing the mandible. For example, if Zhang San's ID in the manufacturer's CRM order management is 123, then the name of Zhang San's first step maxillary model would be: 123U01.

[0037] Each model consists of a model body, positioning keys, and a digital code. Specifically, the thermoforming method in S2 is as follows: two models are thermoformed at once on a circular diaphragm with a diameter of 133mm using a molding machine. During the thermoforming process, the models must be placed within a circular area with a diameter of 115mm, and must not exceed this range. Otherwise, the crown formed at the edge of the molding fixture will be too thin and will not meet clinical requirements.

[0038] To ensure uniform thickness of the dental aligners after heat pressing, the placement requirements for the two models are as follows: the maximum arch width is less than 75mm, the arch width is between 35mm and 75mm, and the distance between the distal ends of the arches is greater than 10mm and less than 25mm. If the arch width is outside these ranges, the two models will exceed the maximum diameter of the pressing platform, making them unsuitable for placement on the entire pressing fixture and thus preventing proper molding. If the distal ends of the arches are outside these ranges, the models produced by double pressing will exhibit material buildup if the distal ends are too close, resulting in protruding material on the aligner and rendering it unusable. If the distal ends are too far apart, the dental models may extend beyond the boundaries of the heat pressing platform.

[0039] Furthermore, using OrthCurve gingival line software (dual-mode cutting version), the maxillary model or mandibular model of the same case from consecutive steps were imported. After import, the coordinate system of the model group was processed in batches, positioning keys were added, corresponding identification numbers were automatically generated, and gingival cutting lines were automatically generated. During export, each maxillary / mandibular model was automatically mirrored to generate the same model at another position on the dual-mode jig. The output result was two STL files for one maxillary model, so that one maxillary model could be placed at any position on the dual-mode jig for subsequent visual scanning to retrieve the corresponding maxillary model.

[0040] Furthermore, the specific method for identifying the braces model in S4 is as follows:

[0041] The visual scanning module identifies the braces positioning keys and digital codes of two braces models, obtains the cutting model and mirror cutting model associated with the digital codes, and matches the cutting positioning keys in the cutting model and the mirror cutting positioning keys in the mirror cutting model with the braces models to obtain the matching results.

[0042] Dental films, as the largest consumable material in braces production, can significantly reduce the production cost of braces by at least 40% and improve the efficiency of the lamination process by 100%, as demonstrated in the examples.

[0043] Standard diaphragm specifications are either round pieces with a diameter of 120mm or 125mm, or square pieces with a side length of 127mm, each capable of producing only one adult brace at a time. According to the diaphragm utilization rate calculation formula: diaphragm area / number of braces that can be made, assuming a 125mm round diaphragm produces one brace at a time, the diaphragm utilization rate is π(125 / 2)² = 3906.25π, while a 133mm round diaphragm produces two braces, with a utilization rate of π(133 / 2)² / 2 = 2211.125π. Therefore, the 133mm round diaphragm utilization rate is 1 - 2211.125π / 3905.25π = 43.38% higher than that of the 125mm round diaphragm. Thus, the diaphragm cost is reduced by 43.38%.

[0044] The molding machine has a cycle time of 1 minute for heating one diaphragm, meaning it can complete the molding of one model in one minute, and two dental aligners can be molded in 2 minutes. The molding machine using 133mm round discs also has a cycle time of 1 minute, but using 133mm round discs allows for the molding of two dental aligners in one operation, reducing the molding time for two dental aligners by 1 minute, thus increasing the molding process efficiency by 100%.

[0045] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A semi-automatic forming and cutting method for fabricating double dental braces using a single diaphragm, characterized in that, Includes the following steps: S1: Generate an orthodontic model group, print the orthodontic model group, and obtain an orthodontic model. The orthodontic model group includes a maxillary model group and a mandibular model group. S2: The orthodontic model is hot-pressed to obtain a braces model, which includes braces positioning keys and digital codes; S3: Import the orthodontic model group into the OrthCurve module, perform positioning processing on the orthodontic model group to obtain the cutting positioning key and gingival cutting line, export the processing results, and obtain the cutting model; S4: The visual scanning module identifies the braces positioning keys and digital codes of the braces model, obtains the cutting model associated with the digital codes, matches the cutting positioning keys in the cutting model with the braces positioning keys, obtains the matching results, obtains the cutting positioning keys and gingival cutting lines associated with the cutting model, generates a processing file based on the matching results, the cutting positioning keys and the gingival cutting lines, inputs the processing file into the cutting machine, and the cutting machine cuts the braces model according to the processing file to obtain the braces; The OrthCurve module in S3 performs a mirror copy of the cutting model to obtain a mirror cutting model, a mirror cutting locator key, and a mirror gingival cutting line. The specific method for identifying the braces model in S4 is as follows: The visual scanning module identifies the braces positioning keys and digital codes of two braces models, obtains the cutting model and mirror cutting model associated with the digital codes, and matches the cutting positioning keys in the cutting model and the mirror cutting positioning keys in the mirror cutting model with the braces models to obtain the matching results.

2. The method according to claim 1, characterized in that, The specific method for hot pressing in S2 is as follows: Two orthodontic models are placed on a pressure mold tray. The maximum arch width of the orthodontic model is less than 75 mm, and the distance between the distal positions of the arches of the orthodontic models is less than 10 mm and less than 25 mm. The orthodontic models are then thermoformed to obtain two braces models.

3. A semi-automatic forming and cutting system for fabricating double dental braces using a single diaphragm, operated using the method described in any one of claims 1-2, characterized in that, It includes a model generation module, a 3D printing module, a laminating machine, an OrthCurve module, a visual scanning module, and a cutting machine, wherein the model generation module generates the orthodontic model set; The 3D printing module prints the orthodontic model set to obtain an orthodontic model. The molding machine hot-presses the orthodontic model to obtain a braces model. The OrthCurve module performs positioning processing on the orthodontic model group to obtain the cutting positioning key and gingival cutting line, thus obtaining the cutting model; The visual scanning module identifies the braces positioning keys and digital codes of the braces model, obtains the cutting model associated with the digital codes, matches the cutting positioning keys in the cutting model with the braces positioning keys to obtain a matching result, obtains the cutting positioning keys and gingival cutting lines associated with the cutting model, and generates a processing file based on the matching result, the cutting positioning keys, and the gingival cutting lines. The cutting machine cuts the dental brace model according to the processing file to obtain the dental brace.

4. The system according to claim 3, characterized in that, The cutting machine and the film pressing machine have the same dimensions and the same positioning hole position.

5. The system according to claim 3, characterized in that, The die-pressing machine has a die-pressing fixture plate with a diameter of 133mm.

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