Method and system for producing dentures using 3D printing

Abstract

The present invention provides a method and system for producing dentures using 3D printing, which relates to the field of digital design and manufacturing. The method comprises: obtaining a 3D denture model of a patient's mouth; generating an optimal printing path using a 3D denture model path optimization algorithm; automatically generating a support structure based on the 3D denture model, the printing path, and the structural characteristics of the 3D denture model; establishing a simulation model; simulating and analyzing the temperature distribution, mechanical properties, support effect, and printing path during the 3D printing process; optimizing and adjusting the printing process based on the prediction of potential problems based on the simulation results to obtain optimized path planning data and adjusted printing parameters; and forming a processing plan to achieve improved precision, performance optimization, and automated control of the denture production process. The closed-loop control combined with an intelligent feedback mechanism not only improves product quality, but also enhances production efficiency and reduces costs, providing a new solution for technological upgrading and industrial application in the field of denture production.

Description

Technical Field

[0001] The present invention relates to the field of digital design and manufacturing, and in particular to a method and system for producing dentures using 3D printing. Background Art

[0002] The application of 3D printing technology (additive manufacturing) in the field of denture processing has made significant progress. Traditional denture production methods rely primarily on mechanical processing methods such as manual carving and milling, which are complex and time-consuming. This is particularly true in the production of customized dentures, which presents significant process limitations. 3D printing technology, through digital modeling and layer-by-layer printing, can quickly and accurately produce dentures that meet patient needs, significantly improving production efficiency and accuracy while reducing production costs.

[0003] At present, the application of 3D printing technology in denture processing generally includes the following steps:

[0004] Digital design: By scanning the patient's oral condition, a personalized denture is designed using CAD (computer-aided design) software.

[0005] 3D printing: Use a specific 3D printer and materials to print out the designed denture model. Common materials include photosensitive resin, ceramics, etc.

[0006] Post-processing: After printing, the denture needs to undergo a series of post-processing operations such as support removal, cleaning, and curing.

[0007] Quality inspection: Check the size, shape, surface quality, etc. of the denture to ensure that it meets the requirements for use.

[0008] Although 3D printing has shown great potential in denture processing, it still faces some technical problems, mainly in terms of printing accuracy, material properties, post-processing effects, and overall production efficiency. Summary of the Invention

[0009] This application achieves precision improvement, performance optimization, and automated control of the production process for denture production through innovations in 3D printing technology, post-processing control, and quality inspection. Closed-loop control, combined with intelligent feedback mechanisms, not only improves product quality but also enhances production efficiency and reduces costs, providing a new solution for technological upgrades and industrial applications in the field of denture production.

[0010] The first aspect disclosed in this application is

[0011] A method for producing dentures using 3D printing, the method comprising:

[0012] Obtaining a 3D denture model of the patient's oral cavity, wherein the 3D denture model can be obtained by obtaining three-dimensional data of the patient's oral cavity through scanning or digitization technology to obtain a 3D denture model;

[0013] Generate the optimal printing path using a 3D denture model path optimization algorithm (e.g., genetic algorithm, dynamic programming), including the printing sequence, layering method, and path for each layer;

[0014] Automatically generate support structures based on the 3D denture model, printing path, and structural features of the 3D denture model (such as thin walls and overhanging parts) to ensure the model is stable and does not deform during printing;

[0015] A simulation model is established to simulate and analyze the temperature distribution, mechanical properties, support effect and printing path during the 3D printing process. Based on the simulation results, possible problems are predicted and the printing process is optimized and adjusted to obtain optimized path planning data and adjusted printing parameters to form a processing plan.

[0016] Furthermore, the method further comprises:

[0017] Control the 3D printer to print through the processing plan;

[0018] Monitor the changes in parameters during the printing process in real time through sensors (temperature, position, speed) to obtain real-time printing data such as temperature, position, speed, etc.

[0019] Compare real-time printing data with the corresponding target set values in the processing plan to monitor possible errors during the printing process;

[0020] Through the feedback control algorithm, real-time adjustment instructions are obtained to dynamically control the printing process, so that the print head position, printing speed, temperature, etc. can be adjusted in real time to correct any deviations.

[0021] Furthermore, the method for establishing the simulation model is as follows:

[0022] Obtaining complete denture design information, including material parameters and printing process data;

[0023] Convert the 3D denture model of the patient's mouth into a finite element mesh model, convert it into a computable geometry, check and repair discontinuities or non-manifold geometry, and mesh the geometry according to the model complexity to obtain a mesh model with uniformly distributed and appropriate density of mesh elements;

[0024] Assign material, process and boundary condition data to the model to obtain a complete model with material properties, heat sources and boundary conditions;

[0025] Define the simulation time step and solution method to obtain a model with complete simulation parameter settings.

[0026] Furthermore, the method of simulating and analyzing the temperature distribution, mechanical properties, support effect and printing path during the 3D printing process, predicting possible problems based on the simulation results, optimizing and adjusting the printing process to obtain optimized path planning data and adjusted printing parameters, and forming a processing plan is as follows;

[0027] Establish a heat conduction model including the print head, printing layer and material, perform thermodynamic simulation, and analyze the changes in temperature distribution during 3D printing;

[0028] Combined with the material's Young's modulus, yield strength, hardness and other information, a mechanical behavior model of the denture model is established, mechanical simulation is performed, and the possible mechanical properties during the denture printing process are analyzed;

[0029] Based on the design of the support structure (such as support density, support connection method, etc.), its effectiveness during the printing process is analyzed through simulation. Based on the analysis results, the design of the support structure is optimized to ensure that the support can effectively withstand the deformation that may occur during the printing process and reduce the waste of support material;

[0030] Combining thermodynamic and mechanical simulation results, possible printing defects are predicted and optimization solutions are provided.

[0031] Furthermore, the method further comprises:

[0032] Obtain denture data after printing;

[0033] Extract the position and structure of the support parts from the printing results and generate a plan for removing the support structures;

[0034] Remove the supporting structure according to the removal plan and obtain the denture model after the support is removed;

[0035] Detect the surface finish of the denture model, evaluate the polishing effect, and generate a polishing plan based on the polishing effect to polish the denture model surface to obtain the polished denture product.

[0036] Furthermore, the method for generating the optimal printing path by using the 3D denture model path optimization algorithm is as follows;

[0037] Obtain a 3D denture model of the patient's mouth;

[0038] Use slicing algorithms to slice the model into two-dimensional layers and save the geometric information of each layer;

[0039] The overall order of the printing path is determined by a genetic algorithm to obtain a global path plan, which includes the printing layer order and starting point information.

[0040] Furthermore, the method further comprises:

[0041] Obtain the global path results of the genetic algorithm and 3D model slice information;

[0042] Apply dynamic programming to optimize the path layer by layer, including smoothing the path and reducing the need for overhanging supports;

[0043] Obtain the optimized global path planning.

[0044] A system for producing dentures using 3D printing, the system comprising:

[0045] Data acquisition module: used to obtain the initial input data of denture processing and provide basic information for subsequent modules;

[0046] Path Generation and Optimization Module: This module is used to generate a global path plan based on the initial input data for denture processing, including the printing sequence, layering method, and path for each layer, using a path optimization algorithm. It also automatically generates support structures based on the global path plan and the 3D denture model.

[0047] Simulation and pre-detection module: used to establish simulation models, simulate and analyze the temperature distribution, mechanical properties, support effects and printing paths during the 3D printing process, and optimize and adjust the printing process based on the prediction of possible problems based on the simulation results to obtain optimized path planning data and adjusted printing parameters to form a processing plan;

[0048] Print execution control module: used to control the 3D printer to process according to the global path planning and support structure.

[0049] In the process of implementing the embodiments of the present application, the inventors found that the prior art still has the following technical problems:

[0050] Path planning is not optimized enough:

[0051] Existing path planning methods are difficult to globally optimize the printing order and starting point, and cannot balance printing efficiency and quality.

[0052] The lack of the ability to dynamically adjust the path may result in lengthy paths or increased support requirements.

[0053] The support structure design lacks intelligence:

[0054] The generation of support structures lacks simulation-based optimization and is designed only through empirical formulas, resulting in material waste or insufficient support effects.

[0055] The local deformation problem in complex denture models cannot be fully considered, which may easily lead to printing failure or difficulty in support removal.

[0056] Printing process control lacks feedback mechanism:

[0057] During the printing process, only data monitoring is performed, and real-time adjustment of parameters is not possible, and dynamic errors cannot be dealt with.

[0058] Simulation results are not fully utilized in process control, and printing quality is highly dependent on process parameters.

[0059] Lack of standardized optimization of post-processing steps:

[0060] The efficiency of support removal and polishing is low, which can easily damage the denture surface and affect the quality of the final product;

[0061] In order to solve the above technical problems, one or more technical solutions provided in this application have at least the following technical effects or advantages:

[0062] This application uses a method based on a combination of genetic algorithms and dynamic programming to globally optimize the printing path, reduce path redundancy, shorten printing time, and reduce the need for support structures, thereby achieving a balance between printing quality and efficiency and significantly reducing problems encountered during the simulation process. It enables the use of simulation technology, integrated thermodynamics and mechanical simulation, to predict possible defects in the printing process and optimize process parameters, in order to comprehensively consider the temperature distribution, mechanical properties and support requirements of the printed model, and to guide printing path optimization, support design and process adjustment, to achieve a technical closed loop for the entire process and generate the final processing plan.

[0063] This application uses sensors to collect real-time printing data (such as temperature, position, speed, etc.), compares it with target set values, and monitors errors. Combined with a feedback control algorithm, it adjusts the print head position, speed, and temperature in real time to achieve dynamic error correction and ensure print accuracy during the printing process.

[0064] This application can automatically extract the position of the support structure and generate a removal plan, reducing the risk of damage to the model during support removal, and generate a polishing plan based on the surface finish assessment results to ensure a smooth denture surface and improve the quality of the finished product.

[0065] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Figure 1 A schematic flow chart of a method for producing dentures using 3D printing provided in an embodiment of the present application.

[0067] Figure 2A schematic diagram of the system structure for producing dentures using 3D printing provided in an embodiment of the present application.

[0068] Description of the accompanying drawings: data acquisition module 10, path generation and optimization module 20, simulation and pre-detection module 30, printing execution control module 40, post-processing module 50. DETAILED DESCRIPTION

[0069] This application provides a method for producing dentures using 3D printing. Through innovations in 3D printing technology, post-processing control, and quality testing, it achieves improved precision, optimized performance, and automated control of the production process. Combined with closed-loop control using an intelligent feedback mechanism, this method not only improves product quality but also enhances production efficiency and reduces costs, providing a new solution for technological upgrades and industrial applications in the field of denture production.

[0070] After introducing the basic principles of this application, various non-limiting embodiments of this application will be specifically described below in conjunction with the accompanying drawings. It should be understood that the specific embodiments described here are only used to explain this application and are not used to limit this application.

[0071] Example 1: Figure 1 As shown, a method for producing dentures using 3D printing, the method comprising:

[0072] S100 obtains a 3D denture model of the patient’s mouth;

[0073] Specifically: the 3D denture model can obtain the three-dimensional data of the patient's mouth through scanning or digitization technology to obtain a 3D denture model file. The file contains geometric data such as vertex coordinates, normal vectors, and facet information (mesh structure) to form a point cloud model, which represents the external shape of the denture. The AI algorithm can be used to automatically repair noise and missing points in the point cloud data to form a continuous and undamaged surface model. The 3D denture model of this method can provide multiple output format support (such as STL, OBJ, PLY) to enhance compatibility with subsequent processes. While generating the point cloud model, the system can automatically identify key areas (such as thin-walled parts, load-bearing areas, and occlusal surfaces) and annotate their attributes for subsequent path planning and support design optimization;

[0074] The S200 generates the optimal printing path through 3D denture model path optimization algorithms (such as genetic algorithms and dynamic programming), including printing order, layering method and path of each layer.

[0075] The specific steps are as follows:

[0076] Obtain a 3D denture model of the patient's mouth;

[0077] Use slicing algorithms to slice the model into two-dimensional layers and save the geometric information of each layer;

[0078] Determine the overall order of the printing path through a genetic algorithm to obtain a global path plan, wherein the global path plan includes the printing layer order and starting point information;

[0079] Obtain the global path results of the genetic algorithm and 3D model slice information;

[0080] Apply dynamic programming to optimize the path layer by layer, including smoothing the path and reducing the need for overhanging supports;

[0081] Obtain optimized global path planning;

[0082] Support structures are automatically generated based on the 3D denture model, printing path, and structural features of the 3D denture model (such as thin walls and overhanging parts) to ensure that the model is stable and does not deform during printing.

[0083] Specifically, this step generates slice geometry data (contour boundaries and key points of each layer) through the 3D denture model of the patient's mouth;

[0084] Slice the 3D model along the Z axis according to the set layer thickness (e.g. 0.1 mm);

[0085] Each layer records the cross-sectional contour (boundary polygon) and key points (such as corners, thin-walled areas), and saves its slice information as a two-dimensional geometric data array, which contains the boundary point set of each layer;

[0086] Obtain initial printing parameters: such as nozzle movement speed, layer thickness, initial position of printing starting point, etc.

[0087] Define optimization goals based on printing requirements.

[0088] like:

[0089] Path Length: Minimize the total path length of the nozzle movement for each layer.

[0090] Start and end point positions: Optimize the distance between the start point of each layer and the end point of the previous layer to reduce non-printing movement between layers.

[0091] Printing efficiency: avoid unnecessary jump paths and improve printing continuity;

[0092] Each individual represents a complete path planning scheme, including the printing order, starting position and direction of each layer;

[0093] Use encoding to represent the path sequence (such as the order in which points are printed) as an array;

[0094] Multiple path planning schemes are randomly generated as the initial population, each of which is composed of geometric information of each layer in the model slice data;

[0095] Based on the path sequence represented by the individuals, the total path length of the nozzle movement was calculated;

[0096] Use geometric algorithms to calculate the actual distance between points and accumulate them to form the path length;

[0097] Calculate the non-printing distance of the inter-layer path (e.g., from the end point of the previous layer to the starting point of the next layer) and add the total path length as a penalty term;

[0098] Evaluate path smoothness, such as the number of inflection points or the frequency of direction changes, and set higher penalty weights for complex paths;

[0099] Combining the above indicators, the fitness value of each individual is calculated. The higher the fitness, the better the path plan.

[0100] Through methods such as roulette wheel selection and tournament selection, individuals with higher fitness are selected from the current population to enter the next generation, so that excellent path plans have a higher probability of being retained;

[0101] Based on the selected high-quality individuals, a part of the path segments is selected from the two path plans for exchange to generate a new path plan to maintain the legitimacy of the path and avoid duplication or omission of points;

[0102] Randomly select a part of the individual's path sequence and make a small adjustment (such as two-point exchange or local reversal) to increase the diversity of the population through mutation operations and prevent it from falling into the local optimal solution;

[0103] After selection, crossover, and mutation operations, the next generation population is generated;

[0104] Evaluate the fitness value of each individual in the new population to find out whether there is a better global path solution.

[0105] If the fitness of the population no longer improves significantly after multiple iterations or reaches the preset number of iterations, the iteration is stopped;

[0106] Obtain the optimal global path planning result, which includes the printing order, starting point position, path direction of each layer, and the connection order of the starting points between layers;

[0107] Obtaining the global path result and 3D model slice information (including slice geometry data and model features) obtained in the genetic algorithm;

[0108] Extract the boundary contours and special points (such as corners or hanging areas) of each layer from the slice data as key points on the path;

[0109] Divide the printing area of each layer into several small grids and record the connection relationship of key points (i.e., which points have optional paths between them);

[0110] Calculate the path length between two points in each grid using geometric algorithms;

[0111] Set additional weights for paths. For example, paths with more direction changes have higher weights, and paths that require additional overhanging supports have higher weights.

[0112] Record the current shortest path weight and path source for each key point;

[0113] Starting from the starting point, update the path one by one, and for each key point, calculate the total weight of the possible paths connecting it to other points (path length + complexity weight).

[0114] If the new path weight is lower than the recorded weight, the path source and cumulative weight of the point are updated;

[0115] When the weights of all points are no longer updated, the path is recorded backtracking;

[0116] For thin-walled areas, paths with fewer direction changes are preferred to reduce vibration and instability of the print head.

[0117] If a path causes the next layer to require more support, reorient the path to reduce overhang areas across layers;

[0118] Output optimized path data: including the starting point of each layer, path sequence, direction, optimized path weight, and printing order adjustment of special areas;

[0119] It can rearrange the path order through dynamic planning to make the print head movement as smooth as possible and reduce the path length.

[0120] Automatically generate support structures based on the 3D denture model, printing path, and structural features of the 3D denture model (such as thin walls and overhanging parts) to ensure the model is stable and does not deform during printing;

[0121] The specific method is as follows:

[0122] Obtain the global path result and 3D model slice information (including slice geometry data and model features) after dynamic planning;

[0123] Analyze the slice geometry data and identify the dangling parts of each layer, that is, the boundary points or polygons of the layer are not directly connected to the previous layer, or the connection area is insufficient to support it. It can use rule analysis (such as normal vector detection) to calculate the dangling boundary points and the area ratio of the dangling boundary points;

[0124] Utilize rule analysis (such as normal vector detection) to calculate the dangling boundary points and the area ratio of the dangling boundary points. This can be done by performing distance calculation on the point set of the contour boundary to determine the area less than a threshold.

[0125] Choose the appropriate support structure type based on the printing material and model complexity, such as:

[0126] Dendritic support: suitable for models that need to support multiple small areas;

[0127] Lattice support: suitable for larger suspended areas that require high stability;

[0128] Point support: suitable for local thin walls or small areas;

[0129] Use overhanging points and thin-walled areas as support starting points and calculate where the supports connect to the print bed or other printed parts to ensure that the contact area between the support structure and the model is large enough to provide support while avoiding interfering with critical geometric parts of the model.

[0130] Design a path based on the generated support points and build the support structure in the printing order;

[0131] Output complete data of the support structure, including point sets, paths, and support geometry, and store it as a 3D model file (such as STL format) to be combined with the denture model;

[0132] Merge the support structure's print path with the original print path to form a complete print plan file;

[0133] S300 establishes a simulation model to simulate and analyze the temperature distribution, mechanical properties, support effect and printing path during the 3D printing process. Based on the simulation results, it predicts possible problems and optimizes the printing process to obtain optimized path planning data and adjusted printing parameters to form a processing plan.

[0134] Specifically, it simulates the 3D printing process by building a simulation model to pre-emptively detect potential issues (such as deformation, insufficient supports, and print failures), and ensures print quality through prediction and optimization. This primarily uses numerical simulation technology, based on data such as material properties, geometry, and print path, to analyze potential physical phenomena during the printing process in advance and provide optimization guidance for the subsequent actual printing process.

[0135] S400 controls the 3D printer to print through the processing plan;

[0136] Monitor the changes in parameters during the printing process in real time through sensors (temperature, position, speed) to obtain real-time printing data such as temperature, position, speed, etc.

[0137] Compare real-time printing data with the corresponding target set values in the processing plan to monitor possible errors during the printing process;

[0138] Through the feedback control algorithm, real-time adjustment instructions are obtained to dynamically control the printing process, so that the print head position, printing speed, temperature, etc. can be adjusted in real time to correct any deviations.

[0139] Specifically, first load the optimized processing plan, which contains all parameters related to the printing process, such as printing path, printing order, layer thickness, temperature setting, etc. These plans are based on the previous steps of path planning, support structure generation, simulation analysis, etc., and are designed to ensure the smooth progress of the printing process.

[0140] According to the processing plan, the 3D printer starts and prints according to the set path and printing order. At this time, the various parameters of the printer (such as nozzle temperature, printing speed, etc.) will be initially controlled according to the preset values;

[0141] During the printing process, sensors (such as temperature sensors, position sensors, and speed sensors) can be installed at key locations on the printer to collect real-time data on changes in various parameters during the printing process.

[0142] For example;

[0143] Temperature sensor: monitors the temperature of the print head, print bed, and material to ensure that the heating part remains within an appropriate range to prevent excessively high or low temperatures from affecting the printing effect.

[0144] Position sensor: monitors the exact position of the print head in real time to ensure that it moves accurately along the predetermined path and avoids deviation from the predetermined route.

[0145] Speed sensor: monitors the movement speed of the print head to ensure it meets the design requirements and avoids material accumulation or surface quality problems caused by excessive speed or slow speed during printing.

[0146] The sensor continuously collects real-time data and transmits it to the system for processing. At this point, the printer will generate a series of real-time printing data, including temperature, position, speed, etc.

[0147] Compare the real-time collected printing data with the target settings preset in the processing plan. These target settings are usually obtained through early steps such as path optimization and simulation modeling;

[0148] Temperature comparison: Compare the actual temperature with the target temperature to determine whether there is overheating or overcooling.

[0149] Position comparison: Compare the current position of the print head with the predetermined path position to detect whether there is a deviation or the print head has deviated from the path.

[0150] Speed comparison: Check the difference between the actual movement speed of the print head and the set speed to ensure that the print head speed remains within the appropriate range to avoid speed fluctuations during printing that affect quality.

[0151] By comparing the results, the system can monitor the errors that may occur during the printing process in real time and determine whether the deviation exceeds the allowable error range. If there is a large error, the system will trigger an adjustment mechanism to avoid a decline in print quality or failure.

[0152] Based on the comparison between the real-time monitoring data and the preset target value, the feedback control algorithm will calculate the instructions that need to be adjusted. For example:

[0153] If the temperature of the print head is too high or too low, the system will adjust the power of the heater or the speed of the cooling fan through feedback instructions to adjust the temperature.

[0154] If the print head's movement position deviates, the system will issue an adjustment instruction to recalibrate the print head's position to ensure that it prints accurately along the path.

[0155] If the printing speed does not meet the setting, the system will adjust the speed of the drive motor to ensure that the printing process maintains a stable speed.

[0156] Feedback control generates corresponding adjustment instructions based on the calculation results, adjusting parameters such as print head position, printing speed, and temperature in real time. These instructions are then sent to the 3D printer's control system to ensure continuous optimization of the printing process. In this way, the system can correct any potential deviations in real time to ensure that the printing quality meets the target.

[0157] During the entire printing process, it continuously monitors data changes through feedback control and makes timely adjustments to ensure that each stage of the printing process is maintained in the optimal state.

[0158] Once any deviation occurs in any link of the printing process, the feedback control system will respond quickly, make adjustments and corrections, thereby ensuring the stability and consistency of printing quality.

[0159] S500 obtains the denture data after printing;

[0160] Extract the position and structure of the support parts from the printing results and generate a plan for removing the support structures;

[0161] Remove the supporting structure according to the removal plan and obtain the denture model after the support is removed;

[0162] Detect the surface finish of the denture model, evaluate the polishing effect, and generate a polishing plan based on the polishing effect to polish the denture model surface to obtain the polished denture product.

[0163] Specifically, after 3D printing is completed, the position and shape of the support structure must be extracted from the print result. Support structures are usually additional materials added to prevent deformation, overhang, or misalignment during the printing process. These structures may include support points, support rods, support layers, etc.

[0164] Using 3D scanning or image processing technology, the printed denture model is scanned to obtain detailed data on its surface and internal structure. This data can be used to accurately identify the position, shape, size, and contact area of the support structure with the denture model. The scan result will generate a 3D point cloud model or mesh model containing the geometric information of the support part.

[0165] By comparing the printing plan with the actual printing results, the support parts that need to be removed are marked, providing accurate data support for subsequent removal steps;

[0166] A detailed removal plan is generated based on the extracted support structure geometry data. The removal plan takes into account the integrity of the denture model, the connection method of the support structure, and the ease of operation during the removal process. The removal plan usually includes the following information:

[0167] Removal order: Start removing the supporting structure from the part that least affects the integrity of the denture, ensuring that the denture model is not damaged during the removal process.

[0168] Demolition method: Determine what tools and techniques will be used for demolition, such as manual demolition, mechanical demolition, laser cutting, etc.

[0169] Note: Consider the strength and connection method of the support parts and give precautions when dismantling to avoid damaging the key parts of the model.

[0170] Demolition path planning: Taking into account the density and connection method of the support structure, the system will also plan the demolition path, select the optimal demolition sequence and tool application to minimize errors and damage during the demolition process;

[0171] According to the generated demolition plan, use appropriate demolition methods to remove the supporting structure. During the demolition process, robotic arms, manual operation or special equipment can be used to ensure that the denture model remains intact after demolition;

[0172] Mechanical removal: Use a robotic arm or mechanical tools to remove the supports in the order indicated in the removal plan, quickly and efficiently;

[0173] Manual removal: If the support structure is complex or delicate, it can be carefully removed by manual operation to ensure that the details of the model are not damaged;

[0174] Obtaining a denture model after removal: After removal is complete, a denture model is obtained without the supporting parts. This model no longer contains the supporting structure, only the main part of the denture, and it retains its original shape and function.

[0175] After removing the support, the surface finish of the denture model is inspected to ensure that the surface is smooth and free of obvious flaws, scratches or printing defects. Common inspection methods include:

[0176] 3D scanning: Scan the denture surface with a high-precision 3D scanner to obtain surface geometry data and check for defects or irregular areas.

[0177] Visual inspection: Use high-resolution visual inspection equipment (such as industrial cameras) to check the surface finish of the denture and combine image processing technology to identify surface defects.

[0178] Tactile testing: In some cases, tactile sensors are used to inspect the denture surface to sense surface smoothness and defects.

[0179] Finish Assessment: Based on the test results, the surface finish of the denture model is evaluated. The assessment includes surface smoothness, defect size, defect location, etc. to ensure that it meets the required quality standards.

[0180] Based on the surface finish test results, the system will automatically generate a polishing plan. The polishing plan will include:

[0181] Polishing tool selection: Select appropriate polishing tools (such as rotary polishing machines, handheld polishing tools, etc.) according to the material, shape and finish requirements of the denture surface.

[0182] Selection of polishing materials: Choose polishing materials suitable for the denture material, such as polishing paste, abrasive, etc., to ensure that the polishing process does not damage the surface.

[0183] Polishing path planning: Plan the path and sequence of polishing operations to ensure that each area is polished evenly and avoid omissions or over-polishing.

[0184] According to the generated polishing plan, use the selected polishing tools and materials to polish the denture model. The purpose of polishing is to improve the smoothness of the denture surface, eliminate minor defects, and enhance the aesthetics and comfort;

[0185] Automatic polishing: Polishing is performed through automated equipment to ensure that every detail area can be accurately operated.

[0186] Manual polishing: For delicate parts, manual operation is adopted to ensure high-precision surface treatment.

[0187] Finished denture after polishing: After polishing, the final denture is obtained. At this point, the denture not only has a smooth surface, but also its structure and shape meet the design requirements and are suitable for the patient to wear.

[0188] Among them, the method of establishing the simulation model is as follows;

[0189] Obtaining complete denture design information, including material parameters and printing process data;

[0190] Convert the 3D denture model of the patient's mouth into a finite element mesh model, convert it into a computable geometry, check and repair discontinuities or non-manifold geometry, and mesh the geometry according to the model complexity to obtain a mesh model with uniformly distributed and appropriate density of mesh elements;

[0191] Assign material, process and boundary condition data to the model to obtain a complete model with material properties, heat sources and boundary conditions;

[0192] Define the simulation time step and solution method to obtain a model with complete simulation parameter settings;

[0193] Specifically:

[0194] Collect complete data for denture design, including material parameters (such as density, thermal conductivity, Young's modulus, etc.) and printing process data (such as printing layer thickness, speed, printing path, etc.);

[0195] Import the 3D denture model of the patient's mouth into the simulation software and convert it into a finite element mesh model suitable for calculation;

[0196] Check the model and repair discontinuous geometry or non-manifold parts to ensure model integrity and computability during meshing;

[0197] Mesh the model based on its complexity. Ensure that the mesh is evenly distributed and select an appropriate mesh density based on the simulation requirements (higher density for complex areas and lower density for simple areas).

[0198] So that it can finally generate a finite element mesh model with uniform distribution and appropriate density;

[0199] Assign the material parameters of the denture (such as elastic modulus, thermal properties, etc.) to the mesh elements so that the model has realistic material properties.

[0200] Define the heat source (such as the temperature of the print head) and boundary conditions (such as fixed boundaries, free boundaries, etc.) in the printing process.

[0201] Combine material properties and process parameters to generate a complete simulation model;

[0202] Define the desired time step for the simulation to ensure a balance between computational stability and efficiency.

[0203] The choice of solution method, such as explicit or implicit, is determined by the simulation accuracy requirements and computing resources.

[0204] Finally, a model with complete simulation parameters is generated, ready to enter the simulation and analysis stage;

[0205] The method for simulating and analyzing the temperature distribution, mechanical properties, support effect and printing path during the 3D printing process, and optimizing and adjusting the printing process based on the prediction of possible problems according to the simulation results to obtain optimized path planning data and adjusted printing parameters to form a processing plan is as follows;

[0206] Establish a heat conduction model including the print head, printing layer and material, perform thermodynamic simulation, and analyze the changes in temperature distribution during 3D printing;

[0207] Combined with the material's Young's modulus, yield strength, hardness and other information, a mechanical behavior model of the denture model is established, mechanical simulation is performed, and the possible mechanical properties during the denture printing process are analyzed;

[0208] Based on the design of the support structure (such as support density, support connection method, etc.), its effectiveness during the printing process is analyzed through simulation. Based on the analysis results, the design of the support structure is optimized to ensure that the support can effectively withstand the deformation that may occur during the printing process and reduce the waste of support material;

[0209] Combining thermodynamic and mechanical simulation results, possible printing defects are predicted and optimization solutions are provided.

[0210] The specific operations are as follows:

[0211] Create a thermal conduction model that includes the print head, printing layers, and materials to describe the transfer and diffusion of heat in the material during the printing process;

[0212] Simulate the dynamic changes in temperature distribution during the printing process, identify thermal stress or material property changes that may be caused by uneven temperature, and optimize the printing path and process parameters through analysis to avoid excessively high or low temperature areas that affect printing quality;

[0213] Based on the material's Young's modulus, yield strength, hardness, etc., a mechanical behavior model of the denture is established to simulate the material's mechanical response during the printing process;

[0214] Through model analysis, possible stress concentration, deformation or cracks that may occur during the printing process are analyzed to ensure the strength and stability of the denture structure;

[0215] Adjust the printing path and process parameters based on the simulation results to avoid mechanical defects in key areas;

[0216] Combined with design parameters such as support density and connection method, simulation analysis is performed on the performance of the support structure during the printing process;

[0217] Determine whether the support structure can effectively support the deformation that may occur during printing, and identify areas with excessive or insufficient support;

[0218] Optimize support design based on simulation results to ensure that the support structure meets printing stability while reducing material waste;

[0219] Combined with the results of thermal conduction simulation and mechanical properties simulation, a comprehensive analysis of possible printing defects (such as warping, cracking, etc.)

[0220] Propose optimization solutions, such as adjusting the printing path, improving support design, optimizing temperature control, etc., to eliminate or reduce potential problems.

[0221] Integrate the optimized path planning data with the adjusted printing parameters to generate the final processing plan for actual printing.

[0222] A system for producing dentures using 3D printing, the system comprising:

[0223] Data acquisition module 11: used to obtain the initial input data of denture processing and provide basic information for subsequent modules;

[0224] Specifically, the data acquisition module includes:

[0225] 3D scanning unit: collects three-dimensional data of the patient's oral cavity and generates a denture design model;

[0226] Material property input unit: records the physical and mechanical properties of the printed material (such as thermal conductivity, hardness, Young's modulus, etc.);

[0227] Process parameter input unit: collect or manually input printing-related parameters (such as printing layer thickness, printing speed, support density, etc.).

[0228] Path generation and optimization module 12: used to generate a global path plan based on the initial input data of the denture processing through a path optimization algorithm, including the printing sequence, layering method and the path of each layer, and automatically generate a support structure based on the global path plan and the 3D denture model;

[0229] Specifically, the path generation and optimization module includes:

[0230] Slicing processing unit: Slice the 3D denture model to generate two-dimensional geometric layer data (including the contour boundary and key points of each layer);

[0231] Path planning unit: Uses genetic algorithms and dynamic programming methods to globally plan the printing path and determine the printing sequence and starting point position;

[0232] Support generation unit: Based on path planning results and model structural characteristics, it automatically generates support structures to ensure printing stability and reduce material waste;

[0233] Simulation and pre-detection module 13: used to establish a simulation model, simulate and analyze the temperature distribution, mechanical properties, support effect and printing path during the 3D printing process, predict possible problems based on the simulation results, optimize and adjust the printing process to obtain optimized path planning data and adjusted printing parameters, and form a processing plan;

[0234] Specifically, the simulation and pre-detection module includes:

[0235] Thermodynamics simulation unit: Establishes thermal conduction models of the print head, printing layers, and materials, and analyzes temperature distribution changes during the printing process.

[0236] Mechanical behavior simulation unit: simulates the force and deformation of the denture during the printing process based on material performance parameters, and analyzes changes in mechanical properties.

[0237] Support effectiveness analysis unit: Verify whether the support design meets the model stability requirements and optimize the support density and connection method.

[0238] Path Defect Prediction Unit: Combines thermodynamic and mechanical simulation results to predict possible printing defects (such as warping, shrinkage, or deformation) and provide optimization suggestions.

[0239] Parameter adjustment unit: Generates adjusted path planning data and printing parameters based on simulation results to form an optimized processing plan.

[0240] Print execution control module 14: used to control the 3D printer to process according to the global path planning and support structure;

[0241] Specifically, the printing execution control module includes:

[0242] Print head control unit: controls the position, speed and nozzle temperature of the print head to ensure accurate execution of the path;

[0243] Sensor monitoring unit: collects key data during the printing process (such as printing temperature, printing speed, and layer thickness) in real time;

[0244] Error detection unit: compares real-time data with target parameters to detect printing errors (such as position deviation and temperature anomaly);

[0245] Feedback adjustment unit: Dynamically adjusts parameters such as print head position, printing speed and temperature through feedback control algorithm to correct deviations.

[0246] Post-processing module 15; used to obtain the denture data after printing, extract the position and structure of the support part from the printing result, generate a removal plan of the support structure, remove the support structure according to the removal plan, and obtain the denture model after the support is removed;

[0247] Then test the surface finish of the denture model, evaluate the polishing effect, and generate a polishing plan based on the polishing effect to polish the surface of the denture model to obtain the polished denture product;

[0248] Specifically, the post-processing module includes:

[0249] Support extraction unit: extracts the position and structure data of the support part from the printing results.

[0250] Support removal plan generation unit: Generates safe and efficient removal plans based on the support structure to avoid damage to the model body.

[0251] Support removal unit: automatically removes the support structure according to the plan to form a denture model after support removal.

[0252] Surface inspection unit: Evaluates the surface finish of dentures and detects the presence of residues or defects.

[0253] Polishing plan generation unit: formulates polishing strategies (such as polishing tools and polishing time) based on surface inspection results.

[0254] Polishing execution unit: automatically or semi-automatically completes the denture surface polishing process to improve the surface quality of the finished product.

[0255] Through the above detailed description of a method and system for producing dentures using 3D printing, those skilled in the art can clearly understand the system for producing dentures using 3D printing in this embodiment. Since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant parts can be referred to the description of the method part.

[0256] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for producing dentures using 3D printing, characterized in that: The method comprises: Obtain a 3D denture model of the patient's mouth; Generate the best printing path through 3D denture model path optimization algorithm; Automatically generate support structures based on the 3D denture model, printing path, and structural features of the 3D denture model; Establishing a simulation model, the method of establishing the simulation model is as follows; Obtaining complete denture design information, including material parameters and printing process data; Convert the 3D denture model of the patient's mouth into a finite element mesh model, convert it into a computable geometric structure, and mesh the geometric structure according to the complexity of the model to obtain a mesh model with uniformly distributed and appropriate density of mesh elements; Assign material, process and boundary condition data to the model to obtain a complete model with material properties, heat sources and boundary conditions; Define the simulation time step and solution method to obtain a model with complete simulation parameter settings; Simulate and analyze the temperature distribution, mechanical properties, support effects, and printing paths during 3D printing. Based on the simulation results, predict potential problems and optimize the printing process to obtain optimized path planning data and adjusted printing parameters to form a processing plan. The specific method is as follows: Establish a heat conduction model including the print head, printing layer and material, perform thermodynamic simulation, and analyze the changes in temperature distribution during 3D printing; Establish a mechanical behavior model of the denture model, perform mechanical simulation, and analyze the possible mechanical properties during the denture printing process; Based on the design of the support structure, analyze its effectiveness during the printing process through simulation, and optimize the design of the support structure based on the analysis results; Combining thermodynamic and mechanical simulation results, possible printing defects are predicted and optimization solutions are provided.

2. A method for producing dentures using 3D printing according to claim 1, characterized in that: The method further comprises: Control the 3D printer to print through the processing plan; Use sensors to monitor changes in parameters during printing in real time and obtain real-time printing data; Compare real-time printing data with the corresponding target set values in the processing plan to monitor possible errors during the printing process; Through the feedback control algorithm, real-time adjustment instructions are obtained to dynamically control the printing process.

3. A method for producing dentures using 3D printing according to claim 2, characterized in that: The method further comprises: Obtain denture data after printing; Extract the position and structure of the support parts from the printing results and generate a plan for removing the support structures; Remove the supporting structure according to the removal plan and obtain the denture model after the support is removed; Detect the surface finish of the denture model, evaluate the polishing effect, and generate a polishing plan based on the polishing effect to polish the denture model surface to obtain the polished denture product.

4. The method for producing dentures using 3D printing according to claim 1, characterized in that: The method for generating the optimal printing path by using the 3D denture model path optimization algorithm is as follows; Obtain a 3D denture model of the patient's mouth; Use slicing algorithms to slice the model into two-dimensional layers and save the geometric information of each layer; The overall order of the printing path is determined by a genetic algorithm to obtain a global path plan, which includes the printing layer order and starting point information.

5. A method for producing dentures using 3D printing according to claim 4, characterized in that: The method further comprises: Obtain the global path results of the genetic algorithm and 3D model slice information; Apply dynamic programming to optimize the path layer by layer; Obtain the optimized global path planning.

6. A system for producing dentures using 3D printing, characterized in that: The system is used to implement the method for producing dentures using 3D printing according to any one of claims 1 to 5, and the system comprises: Data acquisition module: used to obtain the initial input data of denture processing and provide basic information for subsequent modules; Path Generation and Optimization Module: This module is used to generate a global path plan based on the initial input data for denture processing, including the printing sequence, layering method, and path for each layer, using a path optimization algorithm. It also automatically generates support structures based on the global path plan and the 3D denture model. Simulation and pre-detection module: used to establish simulation models, simulate and analyze the temperature distribution, mechanical properties, support effects and printing paths during the 3D printing process, and optimize and adjust the printing process based on the prediction of possible problems based on the simulation results to obtain optimized path planning data and adjusted printing parameters to form a processing plan; Print execution control module: used to control the 3D printer to process according to the global path planning and support structure.

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