Techniques for securing thermoforming models

Abstract

This disclosure discusses techniques for securing thermoforming models, including locator plates (1105, 601, 701) with raised polygonal cuts (502) and locator pins (603, 802) for receiving and securing individual unique dental models, systems for thermoforming orthodontic appliances, and methods thereof.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application Serial No. 63 / 428,923, entitled “Techniques for Securing Thermoform Models,” filed on November 30, 2022. The entire contents of U.S. Provisional Patent Application Serial No. 63 / 428,923 are incorporated herein by reference. Technical Field

[0003] The present technology relates to dental appliance manufacturing technology. More specifically, the present technology relates to a technology for fixing a thermoforming model. Background Art

[0004] Orthodontic braces are appliances designed to make a series of discrete tooth position corrections to properly align the teeth. Braces are equivalent to having brackets / wire brackets for orthodontic treatment, but they have many advantages. For example, braces are typically clear or translucent, comfortable, and removable for cleaning, and they allow patients to eat whatever they want. The manufacture of braces traditionally begins with generating a digital model of the patient's teeth by scanning the patient's teeth or by making a dental impression of the patient's teeth and then scanning the impression. Once the digital model of the patient's teeth has been obtained, a physical dental model can be made (e.g., using 3D printing technology) to provide a positive model of the teeth, also called a dental arch.

[0005] When an intraoral scanning device (IOS device) is used to scan the patient's teeth, a three-dimensional computer-aided design (CAD) representation is imported into custom software that allows the operator to move each tooth in specific, discrete movements to achieve the final corrected dental arch.

[0006] The 3D printed dental arch model is washed and then allowed to dry. Once dried, a polymer is thermoformed on top of the 3D printed dental arch model.

[0007] The thermoformed part is then laser marked with the part identification. The laser marked thermoformed part is then cut by one of several methods so that the aligner that arrives at the customer can be separated from the excess aligner material.

[0008] The aligners are then polished in a part tumbling process to remove burrs and sharp edges. The aligners are inspected and then sealed in bags for shipment to the customer's orthodontist or directly to the patient.

[0009] Previous thermoforming designs have had the following problems: securely positioning the 3D printed dental arch model for forming the heated plastic film with minimal additive material pressure. In addition to having excess material, these designs do not always accurately hold the model. Summary of the Invention

[0010] The present technology solves the above problems by using a locator plate with raised polygonal features and locator pins. In some embodiments, the polygonal features are pentagons with rectangular bases and isosceles triangle tops. The pentagons and locator pins significantly improve retention accuracy while requiring minimal additional material and work for 99.9% of dental arch shapes. The present technology also allows additional manufacturing information to be easily visible as needed. The present technology is significantly more flexible than competing designs while using less material. The present technology also advantageously shows manufacturing information in a more obvious / helpful manner.

[0011] Surprisingly, it was discovered that the raised pentagonal shape is compact enough to fit inside all human dental arches, strong enough not to be damaged or broken during handling, easy to manufacture, quickly displays product orientation, is easy to mate, and has sufficient surface area to hold the parts against rotation. In particular, the pointed end of the pentagon is easy to orient; the shape allows for ergonomic and self-aligning fore-aft loading; and the flat sides of the shape prevent 3D dental arch rotation.

[0012] In one embodiment, the technology involves a locator plate for receiving and securing an individual's unique dental model.

[0013] In some embodiments, the locator plate has a raised pentagon extending from a surface of the locator plate and having a rectangular base and an isosceles triangle top, and a locator pin.

[0014] In some embodiments, the raised pentagon is positioned in the center of the locator plate.

[0015] In some embodiments, the locator pin is spaced apart from the raised pentagon from which the locator pin extends.

[0016] In some embodiments, the locator plate further has a first locator cone, a second locator cone, and a third locator cone spaced apart from the raised pentagon and the locator pin in a triangular arrangement.

[0017] In some embodiments, at least one of the raised pentagon and the locator pin is chamfered.

[0018] In some embodiments, the locator plate has raised lettering spaced apart from the raised pentagon.

[0019] In some embodiments, the locator plate further has a dental model attached to the raised pentagons and the locator pins for forming the dental appliance.

[0020] In some embodiments, the locator plate further comprises a polymer sheet overlying the dental model for forming the dental appliance.

[0021] In one embodiment, the technology relates to a method of thermoforming a dental brace, the method having the steps of: printing a 3D dental model comprising a positive model of a dental arch and a 3D printed locator tab positioned within an interior portion of the dental arch; providing a locator plate having a raised polygon and a locator pin extending from a surface of the locator plate; securing the 3D dental model to the locator plate by positioning the raised polygon within a polygon cutout and the locator pin within the pin cutout; and thermoforming a polymer sheet over the dental model secured to the locator plate.

[0022] In some embodiments, the printing step includes printing an edge of a polygonal cutout within the 3D printed locator tab and printing a boundary of a pin cutout within the 3D printed locator tab.

[0023] In some embodiments, the method further comprises moving the 3D dental model into a proper position for thermoforming by repositioning the locator plate.

[0024] In some embodiments, the raised polygon of the locator plate has an apex oriented towards the cutting portion of the dental arch, which apex indicates the proper orientation of the 3D dental model relative to the raised polygon of the locator plate.

[0025] In some embodiments, the raised polygons of the locator plate and the polygonal cutouts in the 3D printed locator tabs are pentagonal.

[0026] In some embodiments, the step of printing the 3D dental model further comprises 3D printing edges of the cut lettering positioned along one or more edges of the polygonal cut.

[0027] In some embodiments, the printing of the 3D dental model further comprises 3D printing raised lettering positioned along one or more edges of the polygonal cutout.

[0028] In some embodiments, the locator plate further defines three concave locator cones formed within the convex polygon of the locator plate and the surface from which the locator pins extend.

[0029] In some embodiments, the concave locator cones are positioned in a triangular arrangement relative to the convex polygon.

[0030] In some embodiments, the thermoformed polymeric sheet further comprises a portion of the thermoformed polymeric sheet within the concave locator cone.

[0031] In some embodiments, the triangular arrangement of the concave locator cones indicates the orientation of the thermoformed polymer sheet when transferred to the thermoformed polymer sheet.

[0032] In one embodiment, the technology relates to a system for thermoforming orthodontic appliances having: a locator plate having a raised polygon and locator pins extending from a surface of the locator plate; a 3D dental model comprising a positive model of a dental arch, 3D printed locator tabs positioned within an interior of the dental arch; and a heat source for thermoforming a polymer sheet over the 3D dental model once the 3D dental model is secured to the locator plate.

[0033] In some embodiments, the system includes printing a 3D dental model that defines edges of a polygonal cutout in the 3D printed locator tab and boundaries of a pin cutout in the 3D printed locator tab.

[0034] In some embodiments, the 3D dental model is mated to the locator plate by positioning the raised polygon within the polygon cutout and positioning the locator pin within the pin cutout.

[0035] In some embodiments, the 3D printed locator tab includes cutout lettering or raised lettering located along one or more edges of the polygonal cutout.

[0036] In some embodiments, the system further includes a camera for viewing and identifying cutout lettering or raised lettering located along one or more edges of the polygonal cutout.

[0037] In some embodiments, the locator plate further defines three concave locator cones formed within the convex polygon of the locator plate and the surface from which the locator pins extend, the concave locator cones being positioned in a triangular arrangement relative to the convex polygon.

[0038] In some embodiments, the triangular arrangement of the concave locator cones indicates the orientation of the thermoformed polymer sheet when transferred to the thermoformed polymer sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The technology will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0040] Figure 1 Shows a top view of the aligner material being thermoformed on a 3D dental arch model.

[0041] Figure 2 Shows a side view of the aligner material being thermoformed on a 3D dental arch model.

[0042] Figure 3A reverse top view showing the aligner material being thermoformed on the 3D dental arch model.

[0043] Figure 4 Top view showing the raised pentagon and locator pins of the locator plate.

[0044] Figure 5 Top view showing the raised pentagon, locator pins, and lettering of the locator plate.

[0045] Figure 6 A top view showing the raised pentagon, locator pin, three locator cones, and four holes of the locator plate.

[0046] Figure 7 3D top and side views showing the raised pentagon, locator pin, three locator cones, and four holes of the locator plate.

[0047] Figure 8 A top view showing the raised pentagon and cylindrical locator pins of the locator plate.

[0048] Figure 9 Shown is a bottom view of the locator plate.

[0049] Figure 10 Shown are 3D bottom and side views of the locator plate.

[0050] Figure 11 A flow chart illustrating an exemplary method embodiment of a thermoforming technique. DETAILED DESCRIPTION

[0051] The present technology includes a locator plate for receiving and securing an individual's unique dental model, the locator plate having a raised polygonal cutout and locator pins for improved securing a thermoformed model. The technology further includes a system for thermoforming an orthodontic appliance and a method for thermoforming a dental appliance.

[0052] In one example, the technique involves e.g. Figures 1 to 10 A locator plate is shown for receiving and securing an individual's unique dental model.

[0053] In some examples, the locator plate has a raised polygon (e.g., a pentagon) extending from a surface of the locator plate and having a rectangular base and an isosceles triangle top, and a locator pin, such as Figures 1 to 8 In some examples, the raised pentagon is positioned in the center of the locator plate. In some examples, the locator pin is spaced apart from the raised pentagon and extends from the surface of the locator plate.

[0054] In some examples, the locator plate further has a first locator cone, a second locator cone, and a third locator cone spaced apart from the raised pentagon and the locator pin in a triangular arrangement, as shown in FIG. Figure 6 and Figure 7 shown.

[0055] In some examples, at least one of the raised pentagon and the locator pin is chamfered, e.g. Figures 4 to 8 The raised pentagon and chamfered edges of the locator pins help the dental model fit more easily into place.

[0056] In some examples, the locator plate has raised lettering spaced apart from the raised pentagons, e.g. Figure 5 The raised lettering may include a product identifier, a case identifier, a batch identifier, or another type of code used in downstream processing and manufacturing steps during the aligner production process.

[0057] In some examples, the locator plate further has a dental model attached to the raised pentagons and the locator pins for forming a dental appliance. In some examples, the locator plate further has a polymer sheet covering the dental model, such as Figures 1 to 3 shown.

[0058] Specifically, Figure 1 A polymer material 101 is shown being thermoformed onto a dental model 102 attached to a locator plate (not shown) in accordance with the present technology.

[0059] Figure 2 A side view of the polymer material 101 after thermoforming onto the dental model 102 is provided.

[0060] Figure 3 Another top view of polymer material 101 thermoformed onto a dental model 102 is provided.

[0061] exist Figures 1 to 3 In each of the figures, the aligner is shown still attached to the thermoformed product. That is, after the locator plate has been removed, the dental model 102 is still attached to the thermoformed sheet. Furthermore, before the final appliance (i.e., aligner) is ready for use on a particular patient (i.e., the patient corresponding to the attached model), and before finishing work (e.g., trimming, deburring, polishing, etc.) can be performed, the thermoformed polymer material still needs to be cut from the sheet 101 and the dental model removed.

[0062] from Figures 1 to 3 It is also apparent that the polymer material is a thin, thermoformable material. The thickness of the polymer material is not particularly limited, but should be thick enough to be thermoformed around the dental model. Preferably, the polymer material is less than 5 mm thick. More preferably, the polymer material can be between about 0.05 mm and about 5 mm thick.

[0063] Examples of thermoforming materials include, but are not limited to, polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), and other biocompatible polymers with suitable elasticity and plasticity for thermoforming.

[0064] The polymer material 101 may include, for example, multiple layers of polymer materials, such as those described in: U.S. Patent No. 10,549,511; U.S. Patent No. 10,870,263; U.S. Patent No. 10,987,907; U.S. Patent No. 11,325,358; U.S. Patent No. 10,946,630; U.S. Patent Publication No. 2022 / 0118747; PCT Application No. PCT / US2020 / 065928; PCT Application No. PCT / US2022 / 025306; and Provisional U.S. Patent Application No. 63 / 354,998; all of which are incorporated herein by reference in their entirety.

[0065] When a thermoformable material is exposed to heat, the material becomes more pliable, which allows the material to be formed and take on the imprinted shape when sufficient pressure is applied.

[0066] However, it can be challenging to consistently and securely hold a 3D model during thermoforming. The present technology addresses this problem by developing a unique locator plate with locator features designed to assist in securely positioning and cooperating with the dental model for optimal thermoforming.

[0067] Figure 4 A top perspective view of a locator tab 401 with a cutout pentagonal shape 402 formed within a portion of a 3D printed dental model is shown. Figure 1 and Figure 3 As shown, the locator tab can be located within the interior of the dental arch and can be formed during the 3D printing process. In this embodiment, the locator tab 401 includes a pentagonal cutout 402 shaped to be placed around the raised pentagon, and a pin cutout 403 shaped to be placed around the locator pin. After experimenting with various shapes, a pentagonal shape with a rectangular base and an isosceles triangle top was found to provide the best fit and alignment accuracy when mating the dental model with the locator plate. Figure 4 Also shown are pin cutouts 403 which aid in positioning and placing the dental model to ensure excellent alignment. Figure 4 In FIG, both the pin cutout 403 and the pentagon cutout 402 are chamfered. The chamfers make it easier to fit the locator plate to the dental model and reduce the likelihood of flashing or extra material from the 3D printing process affecting a proper fit. In one embodiment, the locator plate has chamfers on the back and sides of the pentagonal shape, which also aids in alignment.

[0068] Figure 5 Another top perspective view of a locator tab 501 having a polygonal cutout 502 in the shape of a pentagon with a rectangular base and an isosceles triangle top and a pin 503 cutout for aiding in positioning and placing a dental model is shown. Figure 5 Also shown is alphanumeric lettering 504 which may be present at various locations on the locator tab 501. This lettering is preferably in the form of raised lettering and is spaced apart from the pentagonal cutout 502. Figure 5 In the embodiment shown, alphanumeric lettering 504 is present at three different locations on the locator tab 501 surrounding the pentagonal cutout 502. The alphanumeric lettering is used to identify and match a specific 3D model. For example, a computer with a detector (e.g., using an optical character recognition camera) can scan the locator tab, read the lettering, and match the dental model based on the lettering instructions, further facilitating a more efficient thermoforming process.

[0069] In one example, the alphanumeric lettering represents the case number and / or step / arch identifier, which can be in the form of an encrypted hexadecimal code. In some embodiments, rather than raised lettering, the lettering can be cut through the entire model to allow for more accurate reading from an optical character recognition camera. In a preferred embodiment, the raised text is at least 1 mm long, which overcomes potential problems in 3D printing. In an alternative embodiment, the lettering is cut completely through the thickness of the positioning plate. Having cut lettering can further reduce the amount of material required during the 3D printing process.

[0070] The distance between the dental arch and the locator tab may vary because each dental arch has a unique anatomical shape. The thermoforming digital software is used in conjunction with the lettering to determine the distance for each dental arch. Based on the known positioning of the dental arch, the software ensures that the lettering is displayed when it merges one or more positioning features with the dental arch.

[0071] Figures 6 to 10 Various exemplary locator plate designs are shown with locator features for positioning and securing to a dental model.

[0072] Figure 6A top perspective view of a locator plate is shown, which includes a raised pentagonal shape 602 extending from the surface of the locator plate 601 and having a rectangular base and an isosceles triangular top with chamfered corners, the raised pentagon being positioned in the center of the locator plate. Adjacent to the pentagonal shape is a cylindrical locator pin 603 spaced apart from the raised pentagon and extending from the surface of the locator plate. A locator cone 604 is spaced apart from the raised pentagon and the locator pin in a triangular arrangement, and mounting holes 605 are spaced apart from the raised pentagon and the locator pin in a square arrangement for mounting the locator plate on a thermoforming system. In some embodiments, the mounting holes 605 can be used to securely mount the locator plate 601 to various components during assembly line manufacturing. The locator cone 604 is another locator feature that assists in the placement of the locator plate relative to the dental model. The locator plate also has smaller holes 606 that allow air that may be trapped between the thermoforming material and the locator plate during the thermoforming process to escape and allow for a more secure fit. In some embodiments, a vacuum system can be incorporated into the thermoforming system that can provide suction through the smaller holes 606 to assist in holding the polymer material securely to the locator plate 601. While Figure 6 Only some of the sides of the raised pentagonal shape 602 are shown to be chamfered, but more or fewer edges of the raised pentagonal shape 602 may be chamfered to assist in positioning the dental model on the locator plate 601. In some embodiments, the locator pin 603 may also have a chamfered upper surface.

[0073] Figure 7 Shown as Figure 7 A three-dimensional perspective view of a locator plate is shown, comprising: a raised pentagonal shape 704 extending from a surface of the locator plate 701 and having a rectangular base and chamfered isosceles triangular top, the raised pentagon positioned in the center of the locator plate; a cylindrical locator pin 705 spaced from the raised pentagon and extending from the surface of the locator plate; locator cones 703 spaced from the raised pentagon and the locator pin in a triangular arrangement; and mounting holes 702 spaced from the raised pentagon and the locator pin in a square arrangement. In some embodiments, the mounting holes 702 can be used to securely mount the locator plate 701 to various components during assembly line manufacturing. Smaller holes and grooves 706 allow air that may be trapped between the thermoformed material during the thermoforming process to escape. In some embodiments, a vacuum system can provide suction through the smaller holes 706 to assist in securely holding the polymer material to the locator plate 701.

[0074] Preferably, the locator cones 703 may be conical recesses in the locator plate 701 and arranged as three cones spaced apart in a triangular formation, such as Figure 6 and Figure 7During the thermoforming process, a portion of the polymer material may be thermoformed into a locator cone 703, resulting in three thermoformed features in the polymer material (examples of these features may be found in FIG. Figure 1 and Figure 3 In some embodiments, these thermoformed pyramidal features can assist in orienting the aligner material and dental model during downstream processing, such as laser marking.

[0075] Figure 8 A top perspective view focusing on the raised polygonal shape 801 and the locator pin 802 is shown. Polygonal shape 802 is preferably compact enough to fit inside all human dental arches and is chamfered for a better fit and to avoid dental model fit issues caused by imperfections in 3D printing. The polygonal cutout is preferably strong enough to resist damage or cracking during handling. Additional advantages of the polygonal shape include ease of manufacture, quick indication of product orientation, ease of assembly, and sufficient surface area to prevent part rotation.

[0076] In a preferred example, the polygon is a pentagonal shape, which is useful because it is optimal for the above criteria. In a more preferred example, the pentagonal shape has a generally rectangular and slightly rounded base and an isosceles triangular top, with the raised pentagon positioned in the center of the locator plate. The point on one end is easy to orient, which allows for ergonomic and self-aligning fore-aft loading action, and the flat side of the rectangular portion of the pentagon helps prevent part rotation. In some embodiments, the point on the raised pentagon 801 can be trimmed or cut off, such as Figure 8 as shown to further assist in fitting the dental model to the locator plate.

[0077] The number of locator features is not limited. In an alternative example, the locator plate has more than one polygonal cutout. In another example, additional locator cutouts, such as additional locator pins, can be used and can be optimized based on the specific design of the thermoforming system employed.

[0078] In one example, digital software is used to determine the distance for each dental arch. The software can help track where the dental arches are located and ensure that all text is displayed when it merges the positioning features with the dental arches.

[0079] The lettering may include a case number and step / arch identifier above the edge of the polygonal cutout. In one example, the lettering is an encrypted hexadecimal code. The lettering may be at the base of the polygon (e.g., a pentagon) and may cut through the entire model to allow for more accurate reading from an optical character recognition camera.

[0080] Can use the convex lettering of any suitable length from locator tab.In preferred example, convex text can be at least 1mm.In preferred example, cut through text cuts through the thickness of locator plate completely.

[0081] The raised polygon, locator pins, and / or locator plate may be chamfered. Chamfers advantageously allow for easier mating. Chamfers also advantageously help reduce the likelihood that any flash or excess material from the 3D printing process will prevent the parts from properly fitting during the thermoforming process. In a preferred example, the locator plate has chamfers on the back and sides of the pentagon to aid in alignment.

[0082] The locator plate may include one or more grooves and / or holes to allow air that may be trapped between the film and the plate to escape during the thermoforming process. These holes may also be used in conjunction with a vacuum system to help hold the polymer material securely to the locator plate.

[0083] In a preferred embodiment, the locator pins are spaced apart from the raised polygon. Spacing the pins apart from the polygon advantageously improves the positioning feature(s) to maintain the dental arch in the correct positioning orientation. Spacing the locator feature(s) advantageously minimizes potential variations in the 3D dental arch dimensions to avoid affecting the thermoforming process. 3D printed parts typically result in some degree of dimensional variation between parts based on printer accuracy. How well the 3D dental arch model is positioned will also affect the accuracy of the laser marking and robotic trimming.

[0084] Figure 9 A bottom perspective view of the bottom of the same locator plate is shown. The mounting holes 901 extend through the entire locator plate and can be arranged in any manner, and are preferably arranged in a square arrangement. The smaller holes 902 and grooves 903 allow air that may be trapped between the thermoformed material during the thermoforming process to escape. These holes 902 and grooves 903 can also be used with a vacuum system to provide suction to hold the thermoformed polymer material securely to the locator plate. The diameter of the smaller holes 902 is not particularly limited. In a preferred embodiment, the smaller holes have a diameter of approximately 0.7 mm.

[0085] Figure 10 A three-dimensional perspective view showing the bottom of the same locator plate. Figure 10 The mounting holes in the are arranged in a square arrangement, but their location can depend on the thermoforming system. The grooves allow air that may be trapped between the thermoforming material during the thermoforming process to escape and are not limited in size.

[0086] The present technology further relates to methods of thermoforming an orthotic appliance.

[0087] In general, the present method is characterized by using a locator plate and a dental model to form a specific, custom patient-specific aligner. The present method may include using a locator plate. As a result of incorporating the locator plate, the advantages of thermoforming are achieved, including excellent fit and accuracy with the dental model.

[0088] In one embodiment, the method of the present technology includes six steps, such as Figure 11 As shown in the flowchart.

[0089] The method begins with preparing a dental model for thermoforming. The dental model (1103) can be made by printing a 3D model. The model can include a positive model of the dental arch and a 3D-printed locator tab. Although the locator tab is not restricted in position, the locator tab matches the corresponding locator cutout. In one embodiment, the locator tab is preferably located inside the interior of the dental arch. Printing can include printing the edges of the polygonal cutout with the 3D-printed tab and printing the boundaries of the pin cutout within the 3D-printed locator tab. These features are printed to match and correspond to the locator tab with the corresponding cutout of the feature.

[0090] Next, a locator plate is provided having locator features as described herein for securing the dental model to the locator plate (1105). Preferred locator features of the locator plate include raised polygons and locator pins extending from the surface of the locator plate to assist in positioning and securing to the 3D model. The locator plate may also include locator cones, which are concave tapered indentations in the locator plate that further assist in properly aligning the locator plate.

[0091] The 3D dental model is then secured to the locator plate (1107) by positioning the locator features within the corresponding cutouts. In a preferred example, the securing step involves positioning the raised polygon within the polygon cutout and the locator pin within the pin cutout. The locator features of the locator plate will always ensure a secure fit with the dental model during the thermoforming process. The 3D model can also be moved into the proper position for thermoforming by repositioning the locator plate.

[0092] Once the locator plate is secured to the dental model and in position, a thermoformable material can be thermoformed over the dental model 1109. The thermoformable material is preferably a polymer / thermoplastic sheet or film that is biocompatible and formable over the dental model upon application of sufficient heat and / or pressure.

[0093] The above-described method may have the following additional exemplary features.

[0094] In one example of the method, the raised polygon has a specific shape that helps ensure a secure fit. For example, the raised polygon of the locator plate can have a vertex oriented toward the incisal portion of the dental arch, which vertex indicates the proper orientation of the 3D dental model relative to the raised polygon of the locator plate.

[0095] In one example of this method, the raised polygons of the locator plate and the polygonal cutouts within the 3D printed locator tabs are pentagons, which are optimal for a fixed dental arch overall.

[0096] Additional features of the locator plate in this method include three concave locator cones formed within the convex polygon of the locator plate and the surface from which the locator pins extend.

[0097] In some examples of the method, the concave locator cones are positioned in a triangular arrangement relative to the convex polygon. The triangular arrangement of the locator cones ensures proper orientation of the locator plate.

[0098] The locator cone can include a thermoformed portion that assists in securing the dental model. Thus, in some examples of the method, the thermoformed polymer sheet further includes a portion of the thermoformed polymer sheet within the concave locator cone. Furthermore, the triangular arrangement of the concave locator cone can indicate the orientation of the thermoformed polymer sheet when transferred to the thermoformed polymer sheet. For example, the orientation of the triangular arrangement of the concave locator cone can have a specific position relative to the cutout of the dental arch model. In such embodiments, knowing the position of the locator cone can indicate the position of the dental arch model.

[0099] The present technology further relates to a system for thermoforming orthodontic appliances, the system having a locator plate having a raised polygon extending from a surface of the locator plate and locator pins. The thermoforming system includes the three-dimensional dental model and the locator plate to manufacture an appliance made of a thermoformable material.

[0100] In addition to methods, the present technology also includes embodiments of thermoforming systems utilizing locator plates.

[0101] Specifically, the system includes a 3D dental model comprising a positive model of a dental arch and 3D-printed locator tabs positioned within the interior of the dental arch. The dental model is based on a digital scan of the patient's teeth or a physical impression of the patient's teeth. Preferably, the dental model is based on a digital scan of the patient's teeth using an iOS device.

[0102] In one example of the system, the system includes a heat source for thermoforming a polymer sheet over the 3D dental model once the 3D dental model is secured to the locator plate. The heat source should sufficiently heat the thermoforming material so that the material is formed over the dental model. The temperature at which the heat is applied depends on the desired thermoforming material.

[0103] In some examples of the system, the system includes printing a 3D dental model that defines edges of a polygonal cutout within the 3D printed locator tab and boundaries of a pin cutout within the 3D printed locator tab.

[0104] In an additional example of the system, a 3D dental model can be mated to a locator plate by positioning a raised polygon within a polygon cutout and a locator pin within a pin cutout. The locator features, including, for example, the raised polygon, the locator pin cutout, and the locator cone, optimize the thermoforming process by precisely orienting the locator plate relative to the dental model for a secure fit as the thermoforming material is heated and pressed onto the dental model.

[0105] In some examples of the system, the 3D-printed locator tab includes cutout or raised lettering positioned along one or more edges of the polygonal cutout. In a preferred example, the lettering is in the form of a hexadecimal code and can be cut through the entire locator plate. The lettering assists in identification and indication to the thermoforming system using any suitable detector, such as a camera with optical character recognition software.

[0106] For identification purposes, the system further includes a camera for viewing and identifying cutout lettering or raised lettering located along one or more edges of the polygonal cutout.

[0107] With respect to the locator plate of the system, in some examples, the locator plate further defines three concave locator cones as locator features formed within the convex polygon of the locator plate and the surface from which the locator pins extend, the concave locator cones being positioned in a triangular arrangement relative to the convex polygon. The triangular arrangement of the concave locator cones is useful for indicating the orientation of the thermoformed polymer sheet when transferred to the thermoformed polymer sheet.

[0108] Specific embodiments and methods for fixing thermoforming molds have been disclosed. However, it will be apparent to those skilled in the art that more modifications other than those already described are possible without departing from the inventive concepts herein. Therefore, the subject matter of the present invention is not limited except in the spirit of the present disclosure. In addition, when interpreting the present disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "include" and "comprising" should be interpreted as referring to elements, parts or steps in a non-exclusive manner, indicating that the referenced elements, parts or steps may exist or be utilized or combined with other elements, parts or steps that are not explicitly referenced.

Claims

1. A locator plate for receiving and securing an individual's unique dental model, the locator plate comprising: a raised pentagon extending from a surface of the locator plate and having a rectangular base and an isosceles triangular top, the raised pentagon being positioned in the center of the locator plate; a locator pin spaced apart from the raised pentagon, the locator pin extending from the surface of the locator plate; as well as Optionally, the first locator cone, the second locator cone and the third locator cone are arranged in a triangle, spaced apart from the raised pentagon and the locator pin.

2. The plate of claim 1, wherein at least one of the raised pentagons and / or locator pins is chamfered.

3. The plate of claim 1 wherein the locator plate includes raised lettering spaced apart from the raised pentagons.

4. The plate of claim 1, further comprising a dental model for forming a dental appliance attached to the raised pentagon and the locator pin.

5. The plate of claim 4, further comprising a polymer sheet overlying the dental model.

6. A method for thermoforming a dental brace, comprising: Printing a 3D dental model including a positive model of a dental arch and a 3D-printed locator tab located within an interior of the dental arch, wherein printing the 3D dental model comprises: printing the edges of the polygonal cutouts within the 3D printed locator tabs, and Print the boundaries of the pin cutouts within the 3D printed locator tabs, providing a locator plate having a raised polygon extending from a surface of the locator plate and a locator pin; securing the 3D dental model to the locator plate by positioning the raised polygon within the polygon cutout and positioning the locator pin within the pin cutout; and A polymer sheet is thermoformed over the dental model secured to the locator plate.

7. The method according to claim 6, further comprising: The 3D dental model is moved into the proper position for thermoforming by repositioning the locator plate.

8. The method of claim 6, wherein the raised polygon of the locator plate has a vertex oriented toward a cutting portion of the dental arch, the vertex indicating a proper orientation of the 3D dental model relative to the raised polygon of the locator plate.

9. The method of claim 8, wherein the raised polygon of the locator plate and the polygonal cutout in the 3D printed locator tab are pentagonal.

10. The method according to claim 6, wherein printing the 3D dental model further comprises: 3D printing the edges of the cutout lettering positioned along one or more edges of the polygonal cutout.

11. The method according to claim 6, wherein printing the 3D dental model further comprises: Raised lettering is 3D printed that is positioned along one or more edges of the polygonal cutout.

12. The method of claim 6, wherein the locator plate further defines three concave locator cones formed within the convex polygon of the locator plate and the surface from which locator pins extend.

13. The method of claim 12, wherein the concave locator cones are positioned in a triangular arrangement relative to the convex polygon.

14. The method of claim 13, wherein thermoforming the polymer sheet further comprises thermoforming a portion of the polymer sheet within the concave locator cone.

15. The method of claim 14, wherein the triangular arrangement of the concave locator cones indicates an orientation of the thermoformed polymer sheet when transferred to the thermoformed polymer sheet.

16. A system for thermoforming an orthodontic appliance, comprising: a 3D dental model comprising a positive model of a dental arch and 3D printed locator tabs positioned within the interior of said dental arch, wherein printing the 3D dental model defines the edges of the polygonal cutout in the 3D printed locator tab and the boundaries of the pin cutout in the 3D printed locator tab, and wherein the 3D dental model is mated to the locator plate by positioning the raised polygon within the polygonal cutout and positioning the locator pin within the pin cutout; and A heat source is provided for thermoforming a polymer sheet over the 3D dental model once the 3D dental model is secured to the locator plate.

17. The system of claim 16, wherein the 3D printed locator tab includes cutout lettering or raised lettering located along one or more edges of the polygonal cutout.

18. The system of claim 17, further comprising: A camera for viewing and identifying the cutout lettering or raised lettering located along one or more edges of the polygonal cutout.

19. The system of claim 16 wherein the locator plate further defines three concave locator cones formed within the convex polygon of the locator plate and the surface from which the locator pins extend, the concave locator cones being positioned in a triangular arrangement relative to the convex polygon.

20. The method of claim 19, wherein the triangular arrangement of the concave locator cones, when transferred to the thermoformed polymer sheet, indicates an orientation of the thermoformed polymer sheet.

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