Manufacturing method and system of personalized orthodontic appliance set treatment scheme

Abstract

The invention relates to a manufacturing method of an orthodontic appliance set, the set comprises at least two appliances with different appliance shell materials, the method at least comprises the following processing steps: a) providing at least two different solid tooth jaw models, each tooth jaw model comprises a substrate and a tooth structure arranged on the substrate, the tooth structure at least defines a part of the current or future tooth structure of the patient, and each model is provided with an independent identification code, and the identification code comprises information at least encoding a specific patient and an appliance shell material; b) putting the at least one solid tooth jaw model provided in the step a) into a deep drawing forming cavity; c) reading the independent identification code on the entity tooth jaw model, and displaying at least the related information of the coded appliance shell material, the reading operation being performed after the step a) and before the step d); d) selecting a corresponding specific appliance shell material according to the coded information in the step c); e) placing the selected shell material of the orthodontic appliance on the solid tooth jaw model, heating the shell material before, during or after placing the shell material, and performing deep drawing forming on the shell material and attaching the shell material to the solid tooth jaw model so as to manufacture a single orthodontic appliance; f) taking out the dental model and the orthodontic appliance from the deep-drawing forming cavity; and g) repeating the steps b) to f) until the processing of each solid tooth jaw model in the set is completed. In addition, the invention also relates to a system for processing an orthodontic appliance set comprising one or more orthodontic appliances.

Description

Technical Field

[0001] This invention relates to a method for manufacturing an orthodontic appliance set, the set comprising at least two appliances made of different appliance shell materials, the method comprising at least the following processing steps: a) Provide at least two different solid dental models, each dental model including a base plate and tooth structures disposed on the base plate, the tooth structures defining at least a portion of the patient's current or future tooth structure, and each model having a unique identification code containing information that at least encodes a specific patient and the material of the orthodontic appliance shell; b) Place at least one solid dental model provided in step a) into the deep drawing cavity; c) Read the unique identification code on the solid dental model and display at least the encoded information related to the orthodontic appliance shell material. This reading operation is performed after step a) and before step d). d) Select the corresponding specific orthodontic appliance shell material based on the information encoded in step c); e) Place the selected appliance shell material on the solid dental model, heat the shell material, wherein the heating operation can be performed before, during or after placing the shell material, and deep-draw the shell material to fit the solid dental model to create a single orthodontic appliance. f) Remove the dental model along with the orthodontic appliance from the deep-drawn cavity; g) Repeat steps b) through f) until the fabrication of each solid dental model in the kit is complete. Furthermore, the present invention also relates to a system for fabricating an appliance kit containing one or more orthodontic appliances. Background Technology

[0002] Orthodontics is the discipline of correcting malocclusion by adjusting the position of teeth. Historically, this type of malocclusion was corrected using orthodontic appliances that applied corrective forces to the teeth. During treatment, these forces moved the teeth into their orthodontically correct alignment. One known way to apply these forces is by using brackets, often referred to as orthodontic brackets. In standard bracket orthodontic treatment, brackets are bonded to each tooth and then connected to an archwire using ligatures. The archwire is flexible and applies the necessary corrective force through the brackets. As an alternative to bracket bonding, dentists can use orthodontic appliances, where brackets remain bonded to the teeth throughout the treatment, while appliances are removable dental devices. Orthodontic appliances are typically provided to patients in a series of different structures. Each appliance progressively adjusts the patient's teeth from their initial position, through intermediate transitional positions, to a final orthodontically normal and aesthetically pleasing position. Appliances are generally made of transparent material, thus providing an "invisible" effect and ease of use. However, to ensure efficiency and error prevention in the manufacturing process, it is necessary to consider situations where the appliance manufactured for a single patient needs to incorporate multiple different tooth structures. Furthermore, the manufacturing difficulty increases further when, in addition to adapting the tooth structure, other characteristics of the appliance need to be accommodated during processing. Such dynamically changing product requirements are difficult to meet using existing orthodontic appliance manufacturing methods, thus greatly increasing the likelihood of manufacturing errors.

[0003] Patent documents also describe various methods for manufacturing orthodontic appliances.

[0004] For example, European patent application EP2467088A1 discloses a method for manufacturing an orthodontic appliance tray, comprising: obtaining an original digital model of a patient's teeth; segmenting the teeth in the digital model; repositioning at least one tooth to a normal alignment position to generate a final tooth model, which represents the final orthodontic position of the teeth; superimposing the final tooth model with the original digital model to generate a digital superimposed model, the starting point of which is the original digital model and the ending point of which is the final tooth model; manufacturing at least one appliance tray based on the superimposed model, such that a tooth receiving cavity is formed in each appliance; and setting at least one force application device in the tooth receiving cavity of at least one appliance tray, which can apply a preset orthodontic force to the target tooth.

[0005] Another patent document, US patent application US2006093982A1, discloses a method for manufacturing a solid orthodontic appliance, including: generating a digital orthodontic appliance model suitable for computer numerical control machining based on a digital dental arch model; dividing the digital orthodontic appliance model into multiple machinable digital components; manufacturing the appliance components using a computer numerical control (CNC) manufacturing method according to the digital components; and assembling the appliance components into a solid orthodontic appliance.

[0006] International patent application WO2021098759A1 discloses a method for manufacturing a dental appliance, which includes: scanning a patient's teeth to generate a 3D printing file; adjusting the 3D printing file according to a treatment plan; printing a dental appliance mold based on the adjusted 3D printing file; and manufacturing the dental appliance using the dental appliance mold.

[0007] The above-mentioned solutions in the existing technology still have room for further improvement, especially in terms of the processing efficiency of serializing different orthodontic appliances and the feasibility of safely handling different orthodontic appliance materials. Summary of the Invention

[0008] Therefore, the objective of this invention is to at least partially overcome the deficiencies of the prior art. Specifically, it provides a method for manufacturing orthodontic appliances that allows for the safe and efficient use of different orthodontic materials. Furthermore, by adapting the orthodontic materials to the individual needs of the patient, the physical performance of the orthodontic appliance set can be enhanced as an additional benefit.

[0009] The above-mentioned objectives of the present invention are achieved by the manufacturing method and system defined in the independent claims. Preferred embodiments of the present invention are described in the dependent claims, the specification, and the drawings, and unless otherwise expressly indicated in the context, the technical features described in the dependent claims, the specification, and the drawings may constitute the scope of protection of the present invention individually or in any combination.

[0010] This invention solves the above-mentioned technical problems by providing a method for manufacturing an orthodontic appliance set, the set comprising at least two appliances made of different appliance shell materials, and the method comprising at least the following processing steps: a) Provide at least two different solid dental models, each dental model including a base plate and tooth structures disposed on the base plate, the tooth structures defining at least a portion of the patient's current or future tooth structure, and each model having a unique identification code containing information that at least encodes a specific patient and the material of the orthodontic appliance shell; b) Place at least one solid dental model provided in step a) into the deep drawing cavity; c) Read the unique identification code on the solid dental model and display at least the encoded information related to the orthodontic appliance shell material. This reading operation is performed after step a) and before step d). d) Select the corresponding specific orthodontic appliance shell material based on the information encoded in step c); e) Place the selected appliance shell material on the solid dental model, heat the shell material, wherein the heating operation can be performed before, during or after placing the shell material, and deep-draw the shell material to fit the solid dental model to create a single orthodontic appliance. f) Remove the dental model along with the orthodontic appliance from the deep-drawn cavity; g) Repeat steps b) to f) until the machining of each solid dental model in the kit is complete.

[0011] The inventors unexpectedly discovered that the aforementioned manufacturing method is highly suitable for safely and efficiently processing different orthodontic appliance materials. In conventional processes, only one type of appliance material is used when fabricating appliances for a single patient. The polymer sheet or polymer laminate appliance material is manually placed in a deep-drawing machine and deep-drawn to fit the patient's specific dental model. Because the material remains uniform throughout the fabrication process for a particular patient, this process is safe and reliable. However, when different material materials are needed for different stages of treatment within the overall treatment plan, manual operation becomes cumbersome and prone to errors—the appropriate appliance material must be selected based on the patient, the dental model, and even, in some cases, the usage time of the same dental model. The high similarity in appearance between different appliance material materials makes it difficult to detect processing errors. Therefore, it is necessary to develop a process to avoid errors in selecting and using appliance material for dental models at specific treatment stages. Only through such adapted and improved processes can complete appliance sets be efficiently manufactured, rather than just individual appliances for the same treatment stage. It was also unexpectedly discovered that by adapting the material of the aligner shell to different stages of the dental treatment plan, more efficient and faster tooth movement can be achieved, which in turn allows for the design of treatment plans with fewer aligners and better orthodontic results.

[0012] The manufacturing method of this invention is used to produce orthodontic appliance sets comprising at least two appliances made of different appliance shell materials. The fabrication of orthodontic appliances typically involves thermoforming a plastic sheet onto a model of the patient's dental structure. This model can be directly fabricated from a virtual model using stereolithography (SLA) equipment or other rapid prototyping equipment, or it can be obtained by machining from a block of material using computer numerical control (CNC). In the treatment plan, a series of positive molds are created, each mold corresponding to a specific future position of the patient's teeth, representing a three-dimensional replica of a target alignment of the teeth during treatment. To achieve effective correction of the patient's teeth, multiple models are usually required. The treatment plan can be divided into different stages, each achieving a different tooth movement target. This staged treatment plan design is practical and can shorten the overall treatment time. Different appliance materials can be selected according to different treatment stages to adapt the appliance material to the treatment target of that stage; therefore, appliances made of different materials are required. Preferably, an orthodontic set comprising one or more orthodontic appliances (preferably made of different appliance shell materials) may contain more than 2 and less than 10 individual orthodontic appliances, more preferably more than 5 and less than 15, and even more preferably more than 10 and less than 20.

[0013] Step a) includes providing at least two different solid dental models, each model comprising a base plate and tooth structures disposed on the base plate, the tooth structures defining at least a portion of the patient's current or future tooth structure, and each model bearing a unique identification code containing information encoding at least a specific patient and the material of the appliance shell. The dental model is a solid model and can be fabricated using any of the methods described in the prior art. This model represents the patient's desired future tooth alignment and can replicate the tooth structure of the maxilla, mandible, or both jaws. Furthermore, the model does not need to replicate the entire dental arch; it can replicate only a portion of the teeth or a specific area of ​​the dental arch. The dental model can be created based on a digital model generated by treatment planning software, in which teeth are digitally adjusted to different stages or to achieve different movement characteristics. According to the digital plan, specific molding foils can be manually or automatically labeled for each fabrication step / model and tooth movement process of the specific material appliance. The solid model includes at least a base plate or pedestal portion, on which specific tooth structures are disposed. In addition, the model or base plate can also replicate a portion of the gingival line or other tooth and oral tissue features. The independent identification code can be visually identifiable, tactilely identifiable, or electronically readable. Therefore, the identification code can store information in multiple ways. Information can be read using visual, tactile, or electronic means. The identification code can store various pieces of information, at least one of which is used for patient identification. Another piece of information is used to indicate at least the specific orthodontic material required for the model. The identification code may also contain information about the multiple materials required for the model, and this information may further include the processing sequence of the available sheet materials. Other information affecting the material properties of the sheet during processing can also be incorporated into the identification code, such as heating time, heating temperature, cooling time, equipment model, sheet temperature before thermoforming, or the surface temperature of the formed foil detected by the equipment temperature detector.

[0014] Step b) involves placing at least one solid dental model provided in step a) into a deep-drawing cavity. The appliance housing is manufactured by deep-drawing the housing material to fit the solid model; to achieve this fit, the model must be placed in the deep-drawing cavity. This cavity provides the necessary process conditions for deep-drawing, typically including applying a vacuum or negative pressure, and / or heating the cavity environment. Furthermore, the cavity is equipped with devices for performing and controlling the deep-drawing process, allowing for adjustment of process time, heating, or decompression gradients.

[0015] Step c) involves reading the unique identification code on the solid dental model and displaying at least the encoded information related to the orthodontic appliance shell material. This reading operation is performed after step a) and before step d). The reading of the encoded information in the unique identification code can be performed before the solid model is placed into the deep-drawing cavity, or during or after placement. The reading method can be selected based on the type of identification code, i.e., acquiring information through visual, electronic, or tactile means. Based on different information acquisition methods, the reading operation can employ electronic means, such as reading information from an RFID chip using a radio frequency identification (RFID) reader. Visual means can also be used, such as reading through a camera or scanner. The information obtained from the identification code can be displayed on a screen. Alternatively, the display can include inputting the information into a computer system for further processing.

[0016] Step d) involves selecting the corresponding specific orthodontic appliance shell material based on the information encoded in step c). In this step, the specified material is selected from a variety of different appliance shell materials. The material for the corresponding model can be manually retrieved from the storage area. In this case, the operator can select the correct material because the correct material for this model is determined by various process steps. Alternatively, the material can be automatically retrieved from the dedicated storage area using equipment such as robots; this step can also be completed using a combination of manual and automated methods.

[0017] Step e) involves placing the selected appliance shell material onto a solid dental model, heating the shell material (this heating can be done before, during, or after placing the shell material), and then deep-drawing the shell material to fit the solid dental model to fabricate a single orthodontic appliance. In this step, the appliance shell material requires physical treatment before deep-drawing. This treatment includes preheating or heating the appliance shell foil. Heating is preferably performed within the forming cavity, but preheated foil can also be placed into the forming cavity and deep-drawn immediately. A preferred method is to first heat the selected appliance shell material, then place it onto the solid dental model and thermoform it to fit the model.

[0018] Step f) involves removing the dental model and orthodontic appliance together from the deep-drawing cavity. Once the shell material has conformed to the model's contours, the near-finished appliance is removed from the model and cavity. Before the appliance is made into a usable final product, it requires post-processing, such as trimming, cleaning, and polishing.

[0019] Step g) includes repeating steps b) to f) until the fabrication of each solid dental model in the kit is completed. To adapt the appliance shell material to different stages of orthodontic treatment, the inventors discovered that appliances made with multiple different shell materials have better orthodontic effects than appliances made with a single material (i.e., using only one shell material throughout the entire treatment process). The entire appliance manufacturing method can be repeated multiple times, and different shell materials can be used for each model at different stages of the treatment plan. Different shell materials give the appliances different physical properties. The corresponding physical properties can be adapted according to the needs of a specific treatment stage. Through repeated processing, the appliance shell material can be flexibly changed based on stored information, and a complete appliance kit for a single patient can be fabricated continuously or in parallel. This achieves lean and efficient processing. Preferably, to fabricate a complete appliance kit required for the entire dental treatment in one go, the process can be repeated more than 5 times, more preferably more than 10 times.

[0020] In a preferred embodiment of this process, an independent identification code can be placed below the substrate of the solid dental model. This placement allows for quick and convenient processing, especially during the model fabrication process when reading the identification code around the deep-drawing equipment. The upper part of the model must be kept clean and in direct contact with the shell material. Therefore, placing the identification code below the model shortens the reading time and reduces the design size of the deep-drawing cavity. The latter advantage is particularly significant because the identification and reading device can be integrated into the bottom of the deep-drawing equipment, thus minimizing the volume of the sealed deep-drawing cavity. This placement also has another advantage: after deep-drawing, the identification code can continue to be used for scanning and identification in automated post-processing steps such as laser cutting and CNC cutting. In this case, the identification code can also contain cutting path information from the laser or CNC equipment. Since there is no forming foil above the identification code, it can still be clearly read / identified in post-processing steps.

[0021] In another preferred embodiment of this process, an independent identification code can be placed at the molar position replicated by the solid dental model. To achieve convenient and reliable placement of the identification code, the inventors found that placing it at the molar position on the upper part of the model is a feasible method. The molar can be the maxillary first molar, maxillary second molar, maxillary third molar, mandibular first molar, mandibular second molar, or mandibular third molar. The identification code at this position will be covered after the aligner is formed and will not be exposed. The identification code can be flat, and during deep-drawing, this flat identification code will not leave an imprint on the aligner shell material. Alternatively, a special bonding method can be used to transfer the imprint of the identification code to the shell material during the aligner forming process. In this case, an identifier will be formed on the aligner shell, providing more information to the user. In this embodiment, the identification code has a dual function. On the one hand, it provides information for aligner processing; on the other hand, it provides relevant information to the user. The identification code can also encode the wearing order of the aligner and the aligner's number in the overall wearing sequence. Furthermore, if the independent identification code is integrated into the molar position on the upper part of the dental model, it can also be placed on the surface of the molar cusp. This placement is the preferred option because placing the identification code at the cusp position has the least impact on the overall force of tooth movement. Any change in the shape of the appliance shell (e.g., local thinning due to the integration of the identification code) may cause different force distributions in the shell material during wear. Therefore, the placement of the identification code in all positions on the dental model does not have the same impact on the force exerted when the appliance is worn. The inventors have found that placing the identification code in the molar position, especially at the molar cusp position, has the least interference with the force distribution achievable by the appliance.

[0022] In a preferred embodiment of this process, the independent identification code may also encode one or more deep-drawing process parameters, selected from heating temperature, heating time, applied pressure, vacuum holding time, post-processing method, or combinations thereof. Depending on the orthodontic material used, each deep-drawing process parameter can be automatically adjusted according to the material type. In this case, all or some specific deep-drawing parameters can be stored in the independent identification code and read before deep-drawing begins. This integrated process reduces the risk of human error during processing. In addition to storing single pressure and / or temperature values, more complex sets of process parameters, such as time-related temperature and / or pressure change curves, can be encoded in the identification code. Furthermore, information from subsequent post-processing steps such as cleaning and cutting can be encoded into the identification code.

[0023] In a preferred embodiment of this process, the orthodontic appliance shell material selected in step e) is selected and placed on the upper part of the solid dental model by means of manual or automatic methods. The inventors have found that selecting and placing the shell material in the form of polymer foil entirely by means of manual or automatic methods is a feasible approach. This strict distinction between manual and automatic operations avoids material confusion and achieves a simple and efficient process flow.

[0024] In a preferred embodiment of this process, step e) involves automatically placing the selected orthodontic appliance shell material onto the solid dental model, and step d) involves the selection of the orthodontic appliance shell material, which includes, based on the displayed coded orthodontic appliance shell material information, using a robotic arm to transfer the specific material from a dedicated storage area to the deep-drawing cavity and place it onto the solid dental model. The automated selection and transfer of the orthodontic appliance material to the deep-drawing cavity offers high practicality. This advantage is particularly pronounced when multiple deep-drawing cavities are operating simultaneously. Due to the continuity of the process flow, placing the wrong material on the wrong model can be effectively avoided. In another preferred embodiment, the robotic arm may also be equipped with an identification code reader to cross-check the information around the model, ensuring that the correct orthodontic appliance foil is transferred to the corresponding model.

[0025] In a preferred embodiment of this process, step f) includes affixing an individual identification label to the orthodontic appliance after deep-drawing and before removing it from the deep-drawing cavity. To facilitate subsequent processing of the manufactured appliance, the inventors found that adding another identification code to the appliance itself is a feasible approach. This identification code or label, affixed to the appliance, can further identify patient information or the order in which the appliance is worn. This label can be a printed code such as a barcode or QR code. Alternatively, it can be an electronic identification code such as an RFID tag loosely affixed to the appliance.

[0026] In a preferred embodiment of this process, the deep-drawing cavity includes at least two independently controllable deep-drawing stations. Steps b) to f) can be performed simultaneously on different solid dental models, and the same or different orthodontic appliance shell materials can be placed in step e). Since the manufacturing method of this invention can safely process a variety of different sheet materials, the inventors have found that setting multiple deep-drawing stations within the deep-drawing cavity is a preferred solution. The function of each deep-drawing station is basically the same as that of the deep-drawing cavity, but it can be independently controlled for specific process parameters such as heating temperature and applied pressure. This arrangement allows for the simultaneous and independent processing of multiple orthodontic appliance materials with significant differences at the same processing location.

[0027] In a preferred embodiment of this process, the simultaneous processing of different dental models is completed automatically, including at least: based on the displayed coded information about the orthodontic appliance shell material, a robotic arm automatically selects specific orthodontic appliance shell material from a dedicated storage area and transfers it to the deep-drawing station, where it is placed on different solid dental models. Automating the necessary steps such as material selection and placement maximizes the efficiency and safety of the processing. In particular, the computer-connected robotic arm enables repeatable and reliable execution of the process.

[0028] In a preferred embodiment of this process, the solid dental model is a model produced by 3D printing. This 3D printing process creates the solid dental model and one or more support structures to ensure the mechanical stability of the 3D-printed dental model, with an independent identification code attached to or integrated into these support structures. The inventors unexpectedly discovered that 3D-printed models are particularly suitable for the manufacturing method of this invention. The 3D-printed dental model requires one or more 3D-printed support structures, which provide mechanical support to the model, maintaining a predetermined relative spacing between the model's components. In conventional processes, these support structures are removed after 3D printing and before deep-drawing to produce the orthodontic appliance. However, the inventors found that retaining this structure during deep-drawing is a feasible approach. Utilizing this support structure, which does not interfere with the deep-drawing process and does not become part of the final orthodontic appliance, mechanical stability of the model during appliance forming can be improved, enhancing the processing quality of the appliance shell because the stability of the 3D-printed model is enhanced. Furthermore, this support structure can also be used to identify the model. Since the support structure is independent of the final appliance, it can be freely encoded with necessary information (such as shell material, patient information, etc.). Information encoding can be achieved by attaching labels to one or more support structures. Alternatively, independent identification codes can be integrated directly into the support structure during the 3D printing process. The latter eliminates the need for additional labeling materials. For example, different printing materials can be used to create barcodes on the support structure, achieving integrated identification codes. Numbers or character sequences can also be printed on the surface of the support structure after its fabrication. An array of support structures can be used to construct identification codes, increasing the storable information capacity through the three-dimensional spacing between different support structures, or directly encoding specific information through this spacing. Information encoding can also be achieved by setting support structures in specific locations. This support structure design simplifies the overall processing and leaves no marks on the model itself. Preferably, the support structure can be located below the molding surface of the dental model, facilitating the reading of information from below the model. This implementation provides more operating space above the model and improves the placement accuracy of the appliance shell material, resulting in a higher quality appliance. In a preferred embodiment, the 3D-printed dental model is a hollow structure containing only a thin printed layer on the tooth surface, with no other printed material below the surface. Only the internal support structure can be installed. The support structure can be located within the cavity below the tooth surface, or (alternatively) as a support connector connecting the last molar of the model to the tooth or to the back of the molar. In the former configuration, the identification code can be read from below the model because the support structure is clearly visible from below. This embodiment allows for convenient information retrieval without occupying upper space during the deep-drawing process. Therefore, using a 3D-printed hollow dental model with an internal support structure simplifies the reading of the identification code integrated into the support structure.Setting the support structure to connect the last few molars or the lower part of the molars in the model can effectively stabilize the model while reading the identification code set on the support structure from the "rear" side of the model.

[0029] In a preferred embodiment of this process, at least five different solid dental models are fabricated, and for each solid dental model, different appliance shell materials are used in steps d) to f). The manufacturing method of this invention is particularly suitable for handling different appliance shell materials, i.e., using different appliances at different stages of dental treatment. By using different foils for molding appliances at different treatment stages, the appliances can have different physical parameters, and suitable physical characteristics can be selected according to the needs of a specific treatment stage. For example, the appliance material used in the rotational orthodontic stage for a single tooth may be different from that used in the tooth height adjustment stage. To achieve faster and more reliable treatment, the inventors have found that fabricating at least five different models is feasible, more preferably at least seven, and even more preferably at least ten.

[0030] The scope of protection of this invention also includes a system for manufacturing an orthodontic appliance kit comprising one or more orthodontic appliances, the system comprising at least: i) Solid dental model assembly unit, which is suitable for continuously assembling one or more dental models, each model including at least a base plate and tooth structures disposed on the base plate; ii) an identification unit adapted to set at least one identification code on a solid dental model, the identification code containing at least information encoding a specific patient and the material of the appliance shell; iii) Deep-drawing forming cavity, which is suitable for reading the identification code on the solid dental model, displaying the encoded orthodontic appliance shell material obtained from the identification code, and deep-drawing the orthodontic appliance shell material to the solid dental model at the deep-drawing forming station to fabricate the orthodontic appliance. iv) Disassembly unit, which is suitable for disassembling and separating orthodontic appliances from solid dental models.

[0031] The inventors unexpectedly discovered that the above-described system can reliably produce a large number of orthodontic appliances in a short time. The core advantage of this system is its ability to safely handle different appliance shell materials, an advantage primarily achieved by features ii) and iii) above, namely, that each dental model can provide accurate identification information containing at least material usage information. For other advantages of this system, please refer directly to the relevant advantages of the manufacturing method of this invention.

[0032] The system of this invention is used to manufacture appliance sets containing one or more orthodontic appliances. This system is particularly suitable for manufacturing different appliances that differ not only in tooth structure but also in the material of the appliance shell. The core of this system is the safe and reliable processing of different shell materials. An appliance set can contain up to 5 appliances, preferably up to 10, more preferably up to 20, and preferably at least 5 different appliance shell materials are used in the processing of these appliances.

[0033] The system includes i) a solid dental model assembly unit suitable for the continuous assembly of one or more dental models, each model comprising at least a base plate and tooth structures disposed on the base plate. This assembly unit can be a standard assembly unit known to those skilled in the art, capable of machining and fixing different tooth components onto the base plate. Different models can also be machined using 3D additive manufacturing processes, i.e., tooth structures can be fabricated using 3D printing. Tooth structures can also be fabricated from block materials using milling processes. The base plate is a generally flat two-dimensional structure on which oral tissue structures are disposed, and the base plate may also contain or replicate some tissue features from the patient's oral cavity.

[0034] The system includes ii) an identification unit adapted to affix at least one identification code to a solid dental model, the identification code containing information encoding at least a specific patient and the material of the orthodontic appliance shell. This identification unit can be a printer, achieving marking by spraying ink onto the model surface. Alternatively, a visually identifiable mark can be formed on the model surface using a laser, i.e., using a laser to alter the visual characteristics of the model surface. An electronically readable chip, such as a radio frequency identification (RFID) chip, can also be affixed to the model surface. This visual, tactile, or electronic identification code can store information in the form of a barcode, QR code, RFID electronic code, etc., containing at least information about the specific patient and information about the shell material (i.e., polymer foil) required for processing the orthodontic appliance corresponding to the model. The identification code may also contain encoded information indicating that the model requires multiple processing steps.

[0035] The system includes iii) a deep-drawing forming cavity adapted to read the identification code on a solid dental model, display the encoded aligner housing material obtained from the identification code, and deep-draw the aligner housing material onto the solid dental model at a deep-drawing station to fabricate an orthodontic aligner. This deep-drawing forming cavity may be equipped with a camera, barcode reader, RFID reader, or other device capable of extracting coded information and providing it to an operator or computer system. It may also contain other standard components of deep-drawing equipment, such as heaters, vacuum devices, and control units for regulating temperature and pressure during program execution.

[0036] The system includes iv) a disassembly unit suitable for separating orthodontic appliances from solid dental models. After deep-drawing and bonding polymer sheets to the dental model, the model needs to be separated from the appliance. This unit may be equipped with devices for peeling or lifting the appliance from the model. It may also perform some post-processing steps, such as trimming, removing excess appliance material, or further stamping, and affixing another identification code to the final appliance.

[0037] In a preferred embodiment of this system, the identification unit may place at least one identification code on the underside of the substrate. Placing the identification code on the underside of the substrate improves model processing efficiency and facilitates code reading, particularly allowing for a more compact design of the deep-drawing cavity, offering significant advantages over placing the identification code on the top of the model. The identification code can also be placed on the side of the substrate without teeth or oral tissue structures. This portion is independent of the deep-drawing process and does not contact any orthodontic appliance housing material. Compared to placing the identification code on the top of the model, reading the code at this location is faster and more convenient.

[0038] In a preferred embodiment of this system, the deep-drawing forming cavity includes a camera unit capable of reading an identification code from below the solid dental model substrate and displaying information related to at least the orthodontic appliance housing material. Reading the identification code from below the model substrate upwards from the bottom of the deep-drawing forming cavity integrates the necessary identification devices into the bottom of the device, eliminating the need for additional components inside the deep-drawing forming cavity. This also facilitates the movement of the orthodontic appliance housing material within the device by increasing the operating space for the material.

[0039] In a preferred embodiment of this system, a computer unit and an automatic feeding unit for orthodontic appliance housing materials are also included. The computer unit receives relevant information about the orthodontic appliance housing materials from the camera unit. The automatic feeding unit receives the relevant information from the computer unit, selects the coded orthodontic appliance housing material from the storage area, and delivers it to the deep-drawing forming station for placement on the actual dental model. Combined with the automatic feeding unit, various materials with significant differences can be processed, and reliable, error-proof orthodontic appliance sets can be assembled. The storage area can store a single type of sheet material in a separate container. The feeding unit can remove the sheet material from the storage location and transport it to the deep-drawing forming cavity, or place it directly into the forming cavity. The feeding unit can transfer the sheet material using an adsorption device or electrostatic force, and can also be equipped with an additional device for detecting the accuracy of the housing material's placement on the model. Furthermore, the system may also include a heating unit for heating the housing material before it is placed on the dental model.

[0040] In a preferred embodiment of this system, an identification unit is also included, which can be used to set an independent identification label for the orthodontic appliance after deep drawing. To ensure that the final processed appliance housing corresponds to a specific wearing sequence, or to match the appliance housing with a specific patient, the inventors have found that setting an identification unit in the system is a feasible approach. This unit can be used to print or laser engrave the required information onto the appliance housing.

[0041] In a preferred embodiment of this system, the deep-drawing forming cavity includes at least two independently operable deep-drawing forming stations, and the overall equipment can easily achieve simultaneous processing of multiple orthodontic appliances. Because the orthodontic housing material corresponding to each model can be accurately identified, processing parameter confusion can be avoided, and the increased process complexity does not lead to an increase in processing errors. Attached Figure Description

[0042] Further details, features, and advantages of the present invention will become apparent from the dependent claims and the following description of the accompanying drawings, which include: Figure 1 A schematic diagram of a manufacturing process of the present invention; Figure 2 : A schematic diagram of the structure of the system of the present invention; Figure 3 Another structural schematic diagram of the system of the present invention; Figure 4 : A schematic diagram of the structure of the system of the present invention; Figure 5 : A schematic diagram of the structure of the system of the present invention; Figure 6 : A schematic diagram of the structure of the system of the present invention. Detailed Implementation

[0043] Figure 1This invention demonstrates a method for manufacturing an orthodontic appliance kit. In step a), at least two different physical dental models 1 are provided. Each model represents the desired future alignment of teeth within the patient's jawbone and includes at least a base plate and tooth structures disposed on the upper part of the base plate. In addition to teeth, model 1 may also replicate other tissue features of the gingiva or the patient's oral cavity. The lower side of the base plate may be flat, while the upper side may contain more personalized tissue features of the patient, with teeth disposed on the upper side of the base plate. Each model 1 has an independent identification code 2, which contains information encoding at least specific patient information and information about the appliance shell material 3. In step b), models 1 are placed continuously or in parallel into a deep-drawing cavity 4. Between the steps of providing model 1 and placing model 1 into the cavity 4, the identification code 2 on model 1 is read. This operation can be performed in a separate step c), or simultaneously before or during placing model 1 into the cavity 4, and this step displays at least the encoded information about the appliance shell material 3. In step d), based on the information encoded in step c), the corresponding specific orthodontic appliance shell material 3 is selected from the appliance shell material storage area. In step e), the selected appliance shell material 3 is placed on the solid dental model 1, and the appliance foil or sheet is deep-drawn. This process may include heating the appliance shell material 3 (the heating operation may be performed before, during, or after placing the shell material 3), and the deep-drawn shell material 3 is then fitted to the solid dental model 1 to fabricate a single orthodontic appliance. After the appliance shell is deep-drawn and fitted to the solid model 1, in step f), the completed appliance is removed from the dental model 1 and the deep-drawn cavity. The above process is repeated at least n times (n is a natural number greater than 1), and each repetition includes at least steps b) to f), until the fabrication of each solid dental model in the kit is completed.

[0044] Figure 2 This invention illustrates a preferred embodiment of the orthodontic appliance kit manufacturing system. The figure shows the simultaneous manufacturing process of three different appliances. First, different physical dental models 1 are provided, each with an independent identification code 2. This code 2 contains at least information about the specific appliance shell material 3 corresponding to that particular dental model 1. The identification code is read using a camera or similar device, and the information about the specific appliance shell material 3 corresponding to that model 1 is displayed on a screen or similar device. A specific appliance shell material 3 is selected from a storage container, heated (if necessary), placed on the physical dental model 1, and deep-drawn. Multiple different appliances can be manufactured in a single process, and these appliances can be made from specific, different shell materials 3. This allows for the simultaneous manufacturing of appliances in stages, and these appliances can possess different physical properties depending on the shell material 3 or the manufacturing method. The selection and placement of the appliance shell material 3 can be done manually.

[0045] Figure 3 This invention demonstrates another feasible implementation of the orthodontic appliance kit manufacturing system. Different appliance shell materials 3 can be stored in a movable storage device. The unique identification code 2 on the dental model 1 is read, and the information of the corresponding appliance shell material 3 is transmitted to the storage system. By moving the storage system, the corresponding shell material 3 is selected for the current dental model 1. After heating the shell material 3, it is placed on the dental model 1 within the deep-drawing cavity 4; alternatively, the shell material 3 can be placed above the dental model 1 and then heated within the deep-drawing cavity 4. The heated shell material 3 is then deep-drawn above the dental model 1 to fabricate the appliance. In this figure, three independent deep-drawing stations 5 are provided within the same deep-drawing cavity 4, allowing the appliance to be removed from the model 1 and further processed as needed.

[0046] Figure 4 This invention demonstrates another feasible implementation of the orthodontic appliance kit manufacturing system. In this process, the selection and placement of the appliance shell material 3 are accomplished by a robotic arm 6. Different appliance shell materials 3 are stored in different storage locations. Based on the coding information on the physical model 1, the robotic arm 6 can select the corresponding material and place the shell material 3 on the corresponding dental model 1, performing deep drawing to form the shell material 3 and fabricating the appliance. This process enables the parallel and safe processing of orthodontic appliances made of different shell materials 3 with different physical properties.

[0047] Figure 5 This invention demonstrates another feasible embodiment of the orthodontic appliance kit manufacturing system. In this system, the selection and placement of the appliance shell material 3 are accomplished by an automatic placement unit 7. This automatic placement unit 7 can retrieve the appliance shell material 3 from a dedicated storage area 8. Different appliance shell materials 3 are stored in different storage locations in the dedicated storage area 8. Based on the coding information on the physical model 1, the automatic placement unit 7 can select the corresponding material and place the appliance shell material 3 on the corresponding dental model 1. Before being placed on the model, the shell material 3 is automatically heated to a preset temperature by the equipment, and the heated appliance shell material 3 is then deep-drawn to manufacture the appliance. This process enables automated, parallel, and safe processing of orthodontic appliances made from different appliance shell materials 3 and possessing different physical properties.

[0048] Figure 6This invention demonstrates another feasible implementation of the orthodontic appliance kit processing system. In this system, different appliance shell materials 3 are stored in different storage locations within a dedicated storage area 8. This dedicated storage area 8 is a movable structure. By moving the storage device, the corresponding appliance shell material 3 is selected for a specific dental model 1 and fed into the processing flow. The unique identification code 2 on the dental model 1 is read, and the information of the corresponding appliance shell material 3 is transmitted to the storage system. The moving storage system 8 selects the corresponding shell material 3 for the current dental model 1. For example, the dental model 1 is placed on a rotary table, and the appliance shell material 3 is placed on top of the dental model 1. The use of this rotary table reduces the size requirements of the processing equipment. The rotary table can move the model to a second station, where the appliance shell material 3 is heated. After heating, the heated appliance shell material 3 is deep-drawn at a third rotary table station. Due to the close proximity of the stations, rapid processing can be achieved, the overall size of the equipment is small, and high production capacity can be realized. The system offers high security because each dental model 1 has an independent identification code 2, ensuring accurate selection of the corresponding orthodontic appliance shell material 3. In addition to the corresponding shell material 3, the identification code 2 can also include other processing information such as heating curves, deep-drawing parameters, and special post-processing methods. This system enables automated, low-cost, and safe manufacturing of orthodontic appliance shells and can flexibly adapt to different shell requirements.

Claims

1. A method of manufacturing an orthodontic appliance set, the set comprising at least two appliances of different appliance shell materials (3), characterized in that, The method includes at least the following processing steps: a) Provide at least two different solid dental models (1), wherein the dental model (1) includes a substrate and a tooth structure disposed on the substrate, wherein the tooth structure at least defines a portion of the patient’s current or future tooth structure, and each model has an independent identification code (2) containing information that at least encodes a specific patient and the orthodontic appliance shell material (3); b) Place at least one solid dental model (1) provided in step a) into the deep drawing cavity (4). c) Read the unique identification code (2) on the solid dental model (1) and display at least the encoded information related to the orthodontic appliance shell material, wherein the reading operation is performed after step a) and before step d); d) Select a specific orthodontic appliance shell material (3) based on the information encoded in step c); e) Place the selected orthodontic appliance shell material (3) on the solid dental model (1), heat the shell material (3), wherein the heating operation can be performed before, during or after placing the selected shell material (3), and deep punch the shell material (3) to fit it onto the solid dental model (1) to make a single orthodontic appliance; f) Remove the dental model (1) and orthodontic appliance together from the deep-filled cavity (4); g) Repeat steps b) to f) until the machining of each solid dental model (1) in the kit is completed.

2. The method according to claim 1, characterized in that, The independent identification code (2) is located below the substrate of the solid dental model (1).

3. The method according to claim 1, characterized in that, The independent identification code (2) is set at the position of the molar replicated by the solid dental model (1).

4. The method according to any one of the preceding claims, characterized in that, In step e), the selected orthodontic appliance shell material (3) is selected manually or automatically and placed on the upper part of the solid dental model (1).

5. The method according to claim 4, characterized in that, In step e), the selected orthodontic appliance shell material (3) is placed on the solid dental model (1) automatically. In step d), the selection process of the orthodontic appliance shell material (3) includes: according to the displayed coded orthodontic appliance shell material information, the specific orthodontic appliance shell material (3) is transferred from the special storage area to the deep drawing cavity (4) by the robotic arm (6) and placed on the solid dental model (1).

6. The method according to any one of the preceding claims, characterized in that, Step f) includes attaching an individual identification label to the orthodontic appliance after the deep drawing is completed and before removing the orthodontic appliance from the deep drawing cavity (4).

7. The method according to any one of the preceding claims, characterized in that, The deep-drawing cavity (4) includes at least two independently controllable deep-drawing stations (5), wherein steps b) to f) are performed synchronously on different solid dental models (1), and the same or different appliance shell materials (3) are placed in step e).

8. The method according to claim 7, characterized in that, The synchronous processing of different dental models (1) is completed in an automated manner, including at least: according to the displayed coded orthodontic appliance shell material information, the robotic arm (6) automatically selects and transfers the specific orthodontic appliance shell material (3) from the dedicated storage area (8) to the deep drawing forming station (5) and places it on different solid dental models (1).

9. The method according to any one of the preceding claims, characterized in that, The solid dental model (1) is a model produced by 3D printing process, wherein the 3D printing process produces the solid dental model (1) and one or more support structures that ensure the mechanical stability of the 3D printed solid dental model (1), wherein the independent identification code (2) is bonded to or integrated into the support structure.

10. A system for manufacturing an orthodontic appliance set comprising one or more orthodontic appliances, characterized in that, The system includes at least: i) Solid dental model assembly unit, wherein the model assembly unit is suitable for continuously assembling one or more dental models (1), each model including at least a base plate and tooth structures disposed on the base plate; ii) an identification unit, wherein the identification unit is adapted to set at least one identification code (2) on a solid dental model (1), wherein the identification code (2) contains information that at least encodes a specific patient and the orthodontic appliance shell material (3); iii) Deep-drawing cavity (4), wherein the deep-drawing cavity is adapted to read the identification code (2) on the solid dental model (1), display the encoded appliance shell material (3) obtained from the identification code (2), and deep-draw the appliance shell material (3) to the solid dental model (1) at the deep-drawing station (5) to make an orthodontic appliance; iv) Disassembly unit, which is suitable for disassembling and separating orthodontic appliances from solid dental models.

11. The system according to claim 10, characterized in that, The identification unit is adapted to have at least one identification code (2) disposed below the substrate.

12. The system according to any one of claims 10 to 11, characterized in that, The deep-drawing cavity (4) includes a camera unit adapted to read the identification code (2) from below the substrate of the solid dental model (1) and display information about at least the orthodontic appliance housing material (3).

13. The system according to claim 12, characterized in that, The system includes a computer unit and an automatic feeding unit for orthodontic appliance housing material; wherein the computer unit is adapted to receive relevant information about the orthodontic appliance housing material (3) from the camera unit; wherein the automatic feeding unit for orthodontic appliance housing material is adapted to receive relevant information about the orthodontic appliance housing material (3) from the computer unit, so as to select the coded orthodontic appliance housing material (3) from the storage area and deliver the orthodontic appliance housing material (3) to the deep drawing cavity (4) and place it on the solid dental model.

14. The system according to any one of claims 10 to 13, characterized in that, The system includes an identification unit, wherein the identification unit is adapted to set an independent identification label on the orthodontic appliance after deep drawing is completed.

15. The system according to any one of claims 10 to 14, characterized in that, The deep drawing forming cavity (4) includes at least two independently operable deep drawing forming stations (5).

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