Method of producing dental object
The method of printing a base structure and intermediate layer with compatible materials addresses the challenges of mechanical damage and distortion in 3D printed dental components, enhancing mechanical strength and simplifying manufacturing processes.
Patent Information
- Application Number
- JP2025096139
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-06-10
- Filing Date
- 2025-06-09
- Publication Date
- 2025-12-22
AI Technical Summary
Three-dimensional printed dental components are prone to mechanical damage, distortion, and deformation during post-processing due to uneven contact surfaces and weak mechanical properties in the unsintered state, making manual handling and machining difficult.
A method involving printing a base structure and an intermediate layer with a support material, followed by printing the dental object, using compatible materials like oxide ceramic and water-soluble wax, to enhance bonding and mechanical strength, allowing for snap-fit assembly and reduced distortion during sintering.
This method improves post-processing efficiency, reduces mechanical damage, and minimizes distortion and deformation, enabling the production of thin dental objects with enhanced mechanical properties and simplified manufacturing.
Smart Images
Figure 2025185728000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a method for manufacturing dental objects and a printer for manufacturing dental objects. [Background technology]
[0002] In three-dimensional printing (3D printing), a component can easily be damaged by a subsequent processing step. An example of this is when a component is removed from the printer's build platform and then another processing step is performed manually. For example, the surface is post-machined to minimize roughness. If a component is polished in an unsintered state, mechanical damage to the component can occur. Cracks can occur, which results in insufficient strength being achieved after sintering.
[0003] Problems arise when debinding and sintering the components due to uneven distribution of contact surfaces, which can lead to distortion of the components and deformation of the components. Therefore, weak components are generally difficult to machine manually because they tend to break in the raw state. The components generally have weak mechanical properties in the unsintered state.
[0004] For post-processing, impression materials or impression kits are usually used, which allow the manufactured components to be post-processed, for example to remove the bar produced during milling or the support body produced during three-dimensional printing. Summary of the Invention [Problem to be solved by the invention]
[0005] It is therefore an object of the present invention to simplify the production of dental objects by three-dimensional printing. [Means for solving the problem]
[0006] The above technical problem is solved by the subject matter of the independent claims. Technically preferred embodiments are the subject matter of the dependent claims, the description and the accompanying drawings.
[0007] According to a first aspect, the aforementioned technical problem is solved by a method for manufacturing a dental object, comprising the steps of printing a base structure; printing an intermediate layer from a support material onto the base structure; and printing the dental object onto the intermediate layer from a manufacturing material for the dental object. This method makes it possible to manufacture thin dental objects, such as ultra-thin veneers. Since the base structure is printed in advance and the dental object is placed on it, post-processing is significantly improved.
[0008] According to a technically preferred embodiment of the method, the production material for the dental object comprises an oxide ceramic material, thereby achieving the technical advantage that, for example, a very compatible production material is used.
[0009] According to another technically preferred embodiment of this method, the support material comprises a water-soluble support material, a wax, and / or a non-ionic surfactant, thereby achieving the technical advantage that, for example, a highly compatible support material is used.
[0010] According to another technically preferred embodiment of the method, the thickness of the intermediate layer is between 0.05 mm and 2 mm, thereby achieving technical advantages such as a good bond between the dental object and the base structure.
[0011] According to another technically preferred embodiment of the method, the shape of the recess in the dental object corresponds to the shape of the base structure, thereby achieving technical advantages, for example, in that a large contact surface is formed between the dental object and the base structure.
[0012] According to another technically preferred embodiment of the method, the base structure is printed with an internal cavity, thereby achieving technical advantages such as saving material for forming the base structure.
[0013] According to another technically preferred embodiment of the method, the cavities of the base structure are filled with support material, which achieves technical advantages, for example, in that the strength of the hollow base structure is increased.
[0014] According to another technically preferred embodiment of the method, the wall thickness of the base structure around the cavity is 1 mm to 3 mm, thereby achieving technical advantages such as a high stability of the base structure.
[0015] According to another technically preferred embodiment of the method, the base structure is printed with a tool interface, which achieves technical advantages, for example, improved handling of the dental object.
[0016] According to another technically preferred embodiment of this method, a base structure is printed from a manufacturing material for a dental object. This achieves the technical advantage of being able to print using a smaller number of different materials. In addition, there is no need to install an additional print head, thus making it possible to manufacture a 3D printer at a lower cost.
[0017] According to another technically preferred embodiment of the method, the support material is removed after printing, thereby achieving the technical advantage that, for example, the dental object can be placed on the base structure in a snap-fit manner.
[0018] According to another technically preferred embodiment of the method, the support material is dissolved after printing, thereby achieving the technical advantage that the support material can be easily removed, for example.
[0019] According to another technically preferred embodiment of this method, the support material penetrates into the dental object after printing, which achieves technical advantages, such as increased strength of the dental object. The support material is absorbed into the porous substance of the manufacturing material and also facilitates grinding and polishing of the dental object, thus automatically creating a smoother surface.
[0020] According to another technically preferred embodiment of the method, the dental object is sintered together with the base structure. Before sintering, the dental object can be polished, which can, for example, reduce distortion or deformation of the dental object during sintering.
[0021] According to a second aspect, the above-mentioned technical problem is solved by a printer for performing the method according to the first aspect, thereby achieving the same technical advantages as the method according to the first aspect.
[0022] According to a third aspect, the aforementioned technical problem is solved by a computer program comprising instructions that, when executed by a printer having a control device, cause the printer to perform the method according to the first aspect, thereby achieving the same technical advantages as the method according to the first aspect.
[0023] Embodiments of the present invention are illustrated by the accompanying drawings and the detailed description set forth below. [Brief explanation of the drawings]
[0024] [Figure 1] FIG. 1 is a schematic diagram showing a printed dental object. [Figure 2] FIG. 1 is a schematic diagram showing a printed dental object. [Figure 3] FIG. 1 is a block diagram illustrating a method for manufacturing a dental object. DETAILED DESCRIPTION OF THE INVENTION
[0025] 1 shows a schematic of a printed dental object formed as a crown. The dental object 100 is printed layer by layer using a moving print head in a three-dimensional printing method. To print the dental object 100 with the base structure 103 and intermediate layers 105, a 3D printer 200 can be used that includes an electronic controller 201 that builds the individual components layer by layer. The controller 201 includes a microprocessor for executing a computer program that controls the printer 200 and its components.
[0026] A sterically matched base structure 103 is printed underneath the dental object 100. The printed base structure 103 is printed from the same manufacturing material 107 as the dental object 100. Alternatively, a different material can be used to print the base structure 103.
[0027] The base structure 103 can have the shape of the remaining root portion of a damaged or treated natural tooth for creating a crown, bridge, or other dental prosthesis. The remaining tooth serves as a foundation for the new dental prosthesis to be placed on it. The function of the remaining tooth is to provide a stable and strong foundation for the dental prosthesis while maintaining the natural aesthetics and function of the dentition. A dentist or dental technician shapes and prepares the remaining tooth to ensure that the dental prosthesis can be placed on it.
[0028] A thin intermediate layer formed of a support material 109 is printed between the dental object 100 and the base structure 103. The intermediate layer has a thickness of, for example, 0.05 mm to 2 mm and can be removed later. The support material 109 can be, for example, a water-soluble support material, wax, and / or a non-ionic surfactant. The base structure 103 can be printed with an internal cavity 113, which can also be filled with the support material.
[0029] Depending on their origin, waxes can be divided into three main groups: natural waxes, chemically modified waxes, and synthetic waxes. Within natural waxes, a distinction is made between vegetable and animal waxes, mineral waxes, and petrochemical waxes.
[0030] In the present invention, petrochemical waxes such as paraffin wax (solid paraffin), petrolatum, microwax (microparaffin), and mixtures thereof are preferably used, and paraffin wax is particularly preferred.Vegetable waxes such as candelilla wax, carnauba wax, Japan wax, espartograss wax, cork wax, guaruma wax, rice germ oil wax, sugarcane wax, ouricury wax, and montan wax; animal waxes such as beeswax, shellac wax, spermaceti, lanolin (wool wax), and brush grease; mineral waxes such as ceresin and ozokerite (earth wax); chemically modified waxes such as montan ester wax, sasol wax, and hydrogenated jojoba wax; and synthetic waxes such as polyalkylene wax and polyethylene glycol wax can also be used.
[0031] Examples of nonionic surfactants include fatty alcohol ethoxylates, fatty alcohol propoxylates, alkyl glucosides, alkyl polyglucosides, octylphenol ethoxylates, and nonylphenol ethoxylates.
[0032] Once printing is complete, the support 109 is removed again, causing the intermediate area between the dental object 100 and the base structure 103 to shrink. This allows the dental object 100 to be placed on the base structure 103 in a snap-fit manner. This has the advantage that stresses applied during processing are distributed over the entire contact surface, improving mechanical properties. Breakage of the dental object 100 during processing can be reduced because the dental object 100 has a large contact surface on the base structure 103 and therefore no point loads occur.
[0033] Typically, the front surface of the dental object 100 is pre-polished once more, thus reducing the time required for polishing in the sintered state. By using this method, the polishing time can be reduced by a factor of four. The reject rate can be reduced by half. Furthermore, the above advantages apply to all manufactured dental objects 100 that are post-processed or reheated after printing.
[0034] Printing the base structure 103 is also extremely advantageous for the sintering process, as it minimizes distortion of the dental object 100. The contact surface is constant and evenly distributed, thus reducing the contact load per square centimeter, which also reduces distortion during sintering or, in the case of lithium disilicate, crystallization.
[0035] The advantage of this method is that no time is lost during printing. It makes no difference in terms of time whether a base structure 103 or a support material 109 is printed underneath the dental object 100. Overall, no additional time is required for printing the dental object 100.
[0036] Another advantage is that a tool adapter can be printed in the base structure 103, which allows it to be accommodated in or engaged with a tool. To this end, the base structure 103 is provided, for example, with a suitably formed recess as a tool interface, which allows the base structure 103 to be clamped or inserted into a tool, so that the dental object 100 can be reliably and easily polished. Post-processing in automated machines, such as CNC machine tools or barrel polishing machines, is also possible.
[0037] On the other hand, the interior of the base structure 103 can be printed hollow and configured with a specific wall thickness, for example, 1 mm to 3 mm. This allows for savings in manufacturing material 107. As a result, a cavity can be printed, which can be filled with a support material 109. To save material for the base structure 103, the support structure 103 fills only the recess 111 in the dental object 100 and does not have an additional design height below the dental object 100 in the vertical direction. The base structure 103 improves manual post-processing and reduces sintering distortion of the dental object 100. Post-processing thin dental objects 100 before sintering is difficult. Without the base structure, some dental objects 100 would be impossible to process because they would break during pre-polishing.
[0038] Thus, the use of three-dimensional printing simplifies the manufacture of dental objects 100, such as dental prostheses or dentures. The intermediate layer 105 functions to prevent distortion and to allow polishing of dental objects 100 with thin wall thicknesses.
[0039] This method allows thinner dental objects 100 to be sintered with less sintering distortion. Different material compositions do not affect this method. The low sintering distortion is due to the fact that the base structure 103 has the same geometry as the dental object 100. This results in a large contact surface and low point loads.
[0040] 2 shows a schematic of another dental object 100 formed from a veneer. The dental object 100 can be operated and processed with a printed base structure 103. The interface between the dental object 100 and the base structure 103 allows stress to be conducted without damaging the dental object 100.
[0041] 3 shows a block diagram of a method for manufacturing a dental object 100. The method includes step S101 of printing a base structure 103. In step S102, an intermediate layer 105 is printed on the base structure 103 from a support material 109. In step S103, the dental object 100 is printed on the intermediate layer 105 from a manufacturing material 107 for the dental object 100. The individual steps S101 to S103 can be performed simultaneously as part of layer-by-layer printing.
[0042] This method can be used to print thinner and more fragile dental objects 100, and the base structure 103 facilitates subsequent processing and polishing of the dental object 100. The use of three-dimensional printing methods simplifies and reduces the labor involved in manufacturing dental objects 100, such as dental prostheses or dentures.
[0043] All of the features described and illustrated in relation to individual embodiments of the invention can also be the subject of the invention in various combinations, whereby simultaneous advantageous results are achieved.
[0044] All method steps may be performed using apparatus suitable for performing each method step. All functions performed by the feature of interest may be method steps in this method.
[0045] The scope of protection of the present invention is defined by the appended claims and is not limited by the features described or shown in the description. [Explanation of symbols]
[0046] 100 Dental Objects 103 Basic structure 105 Middle Class 107 Manufacturing materials 109 Support material 111 recess 113 Cavity 200 printers 201 Control device
Claims
1. Print the base structure; printing an intermediate layer from a support onto the base structure; printing a dental object onto the intermediate layer from a manufacturing material for the dental object; A method for manufacturing a dental object comprising the steps:
2. 10. The method of claim 1, wherein the manufacturing material for the dental object comprises an oxide ceramic material.
3. 10. The method of claim 1, wherein the support material comprises a water-soluble support material, a wax, and / or a non-ionic surfactant.
4. 2. The method of claim 1, wherein the thickness of the intermediate layer is between 0.05 mm and 2 mm.
5. The method of claim 1 , wherein the shape of the recess in the dental object corresponds to the shape of the underlying structure.
6. The method of claim 1 , wherein the substructure is printed to have an internal cavity.
7. 7. The method of claim 6, wherein the cavity in the base structure is filled with support material.
8. 7. The method of claim 6, wherein the wall thickness of the base structure around the cavity is between 1 mm and 3 mm.
9. The method of claim 1 , wherein the substructure is printed to have a tooling interface.
10. 10. The method of claim 1, wherein the base structure is printed from a manufacturing material for the dental object.
11. The method of claim 1 wherein the support is removed after printing.
12. 10. The method of claim 1, wherein the support material dissolves after printing.
13. 2. The method according to claim 1, wherein after printing the support material is infiltrated into the dental object and / or the dental object is sintered together with the base structure.
14. A printer for carrying out the method according to any one of claims 1 to 13.
15. A computer program comprising instructions which, when executed by a printer having a control device, are operative to cause the printer to carry out the method of any one of claims 1 to 13.