Techniques for fixing thermoformed models

Abstract

The present disclosure describes techniques for securing thermoformed models, including locator plates (1105, 601, 701) for receiving and securing individually unique dental models having raised polygonal cutouts (502) with locator pins (603, 802), and systems and methods for thermoforming orthodontic aligners.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and claims the benefit of U.S. Provisional Patent Application No. 63 / 428,923, entitled "Technques for Securing ThermoFORM Models," filed November 30, 2022. The entire contents of U.S. Provisional Patent Application No. 63 / 428,923 are incorporated herein by reference.

[0002] The present technology relates to dental appliance manufacturing techniques, and more particularly, to techniques for fixing thermoformed models. [Background technology]

[0003] Orthodontic aligners are appliances intended to make a series of individual tooth position corrections aimed at properly aligning teeth. Aligners are comparable to having brackets and wire appliances for orthodontic treatment, but they offer many advantages. For example, aligners are often transparent or translucent, comfortable to wear, removable for cleaning, and allow patients to eat what they want. Aligner manufacturing traditionally begins with generating a digital model of the patient's teeth, either by scanning them or by making a dental impression of the patient's teeth and then scanning that impression. Once a digital model of the patient's teeth is obtained, a physical dental model can be fabricated (e.g., using 3D printing) to provide a positive model of the teeth, also known as a dental arch.

[0004] When using an intraoral scanning device (an IOS device) to scan a patient's teeth, a 3D computer-aided design (CAD) representation is imported using custom software that allows the operator to move each tooth with specific, individual movements to achieve the final arch of aligned teeth.

[0005] The 3D printed arch model is washed and then allowed to dry, after which a polymer is thermoformed over the top of the 3D printed arch model.

[0006] The thermoformed part is then laser marked with part identification information, and the laser-marked thermoformed part is then cut by one of several methods so that the aligner to be provided to the customer can be separated from the excess aligner material.

[0007] The aligners are then polished in a part-tumbling process to remove burrs and sharp edges. The aligners are inspected, then bagged, sealed, and shipped to the customer's orthodontist or directly to the patient.

[0008] Previous thermoforming designs had issues with reliably positioning the 3D printed arch model to press the heated plastic film with minimal added material. In addition to creating excess material, these designs did not always hold the model accurately. Summary of the Invention

[0009] The present technology solves the above problems by using a locator plate with a raised polygonal feature and locator pins. In some embodiments, the polygonal feature is a pentagon with a rectangular base and an isosceles triangular top. The pentagonal shape and locator pins greatly improve retention accuracy while minimizing the additional material required and function on 99.9% of arch shapes. The present technology also allows for easy visualization of additional manufacturing information, if needed. The present technology is significantly more flexible while using less material than competing designs. The present technology also advantageously presents manufacturing information in a clearer / more informative manner.

[0010] Surprisingly, the raised pentagon shape is compact enough to fit inside all human dental arches, robust enough not to be damaged or broken during processing, easy to manufacture, provides fast product orientation, is easy to fit, and has sufficient surface area to prevent parts from rotating. In particular, the pointed ends of the pentagon are easy to align. The shape allows for an anterior-to-posterior loading motion that is ergonomic and self-aligning. The flat surfaces of the shape prevent 3D arch rotation.

[0011] In some embodiments, the present technology is directed to a locator plate for receiving and securing an individually unique dental model.

[0012] In some embodiments, the locator plate has a raised pentagon extending from the surface of the locator plate, with a rectangular base and an isosceles triangular top, and a locator pin.

[0013] In some embodiments, the raised pentagon is located in the center of the locator plate.

[0014] In some embodiments, the locator pins are spaced apart from the raised pentagon, and the locator pins extend from the surface of the locator plate.

[0015] In some embodiments, the locator plate further includes 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.

[0016] In some embodiments, at least one of the raised pentagon and the locator pin is chamfered.

[0017] In some embodiments, the locator plate has raised letters spaced apart from the raised pentagon.

[0018] In some embodiments, the locator plate further includes a dental model attached to the raised pentagon and locator pins to form the dental aligner.

[0019] In some embodiments, the locator plate further comprises a polymer sheet that is stretched over the dental model to form the dental aligner.

[0020] In one embodiment, the present technology is directed to a method of thermoforming a dental aligner, the method comprising: printing a 3D dental model including a positive model of a dental arch and 3D printed locator tabs positioned inside the dental arch; providing a locator plate having a raised polygon and locator pins extending from a surface of the locator plate; fixing 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 notch; and thermoforming a polymer sheet over the dental model fixed to the locator plate.

[0021] In some embodiments, the printing step includes printing edges of polygonal cutouts in the 3D printed locator tabs and printing boundaries of pin cutouts in the 3D printed locator tabs.

[0022] In some embodiments, the method further includes moving the 3D dental model to an appropriate position for thermoforming by repositioning the locator plate.

[0023] In some embodiments, the raised polygon of the locator plate has an apex directed toward the incisal edge of the dental arch, which apex indicates the proper orientation of the 3D dental model relative to the raised polygon of the locator plate.

[0024] In some embodiments, the raised polygon of the locator plate and the polygonal cutout in the 3D printed locator tab are pentagonal.

[0025] In some embodiments, the step of printing the 3D dental model further comprises 3D printing edges of cutout letters positioned along one or more edges of the polygonal cutout.

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

[0027] In some embodiments, the locator plate further defines three recessed locator cones formed in the surface of the locator plate from which the raised polygon and locator pins extend.

[0028] In some embodiments, the recessed locator cones are positioned in a triangular arrangement relative to the raised polygon.

[0029] In some embodiments, thermoforming the polymer sheet further comprises thermoforming a portion of the polymer sheet within a recessed locator cone.

[0030] In some embodiments, the triangular arrangement of the recessed locator cones, when transferred to a thermoformed polymer sheet, indicates the orientation of the thermoformed polymer sheet.

[0031] In one embodiment, the present technology is directed to a system for thermoforming an orthodontic aligner, the orthodontic aligner comprising: a 3D dental model including a raised polygon, locator pins extending from a surface of a locator plate, a positive model of a dental arch, and 3D printed locator tabs positioned within the dental arch; and a heat source for thermoforming a polymer sheet onto the 3D dental model once secured to the locator plate.

[0032] In some embodiments, the system includes printing a 3D dental model that defines edges of polygonal cutouts in the 3D printed locator tabs and boundaries of pin notches in the 3D printed locator tabs.

[0033] In some embodiments, the 3D dental model mates with the locator plate by positioning the raised polygon in the polygon cutout and the locator pin in the pin cutout.

[0034] In some embodiments, the 3D printed locator tab includes cutout or raised letters positioned along one or more edges of the polygonal cutout.

[0035] In some embodiments, the system further includes a camera for viewing and identifying cut-out or raised characters positioned along one or more edges of the polygonal cut-out.

[0036] In some embodiments, the locator plate further defines a raised polygon and three recessed locator cones formed in a surface of the locator plate from which the locator pins extend, the recessed locator cones being positioned in a triangular arrangement relative to the raised polygon.

[0037] In some embodiments, the triangular arrangement of the recessed locator cones, when transferred to a thermoformed polymer sheet, indicates the orientation of the thermoformed polymer sheet.

[0038] The present technology will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0039] [Figure 1] Shows a top view of the aligner material being thermoformed on a 3D arch model. [Figure 2] A side view of the aligner material being thermoformed on a 3D arch model is shown. [Figure 3] Shown is a top view of the reverse side of the aligner material thermoformed on a 3D arch model. [Figure 4] FIG. 10 shows a top view of the raised pentagons and locator pins of the locator plate. [Figure 5]1 shows a top view of the raised pentagon, locator pins, and lettering of the locator plate. [Figure 6] A top view of the locator plate's raised pentagon, locator pin, three locator cones, and four holes is shown. [Figure 7] A top-down, angled 3D view of the locator plate's raised pentagon, locator pin, three locator cones, and four holes is shown. [Figure 8] FIG. 10 shows a top view of the raised pentagonal and cylindrical locator pins of the locator plate. [Figure 9] FIG. 10 shows a bottom view of the locator plate. [Figure 10] A 3D view of the locator plate seen from below at an angle is shown. [Figure 11] 1 shows a flow chart of an exemplary method embodiment of a thermoforming technique. DETAILED DESCRIPTION OF THE INVENTION

[0040] The present technology includes a locating plate for receiving and securing an individually unique dental model having raised polygonal cutouts along with locator pins for improved fixation of the thermoformed model. The present technology also includes a system for thermoforming a dental aligner and a method for thermoforming a dental aligner.

[0041] In one example, as shown in FIGS. 1-10, the present technology is directed to a locator plate for receiving and securing an individually unique dental model.

[0042] In some embodiments, as shown in Figures 1-8, the locator plate has a raised polygon, such as a pentagon, extending from the surface of the locator plate, with a rectangular base and an isosceles triangular top, and a locator pin. In some examples, the raised pentagon is located in the center of the locator plate. In some examples, the locator pin is spaced from the raised pentagon, and the locator pin extends from the surface of the locator plate.

[0043] In some examples, as shown in Figures 6 and 7, the locator plate further includes a first locator cone, a second locator cone, and a third locator cone spaced apart from the raised pentagon in a triangular arrangement.

[0044] In some embodiments, at least one of the raised pentagon and the locator pin is chamfered, as shown in Figures 4-8. The chamfered edges of the raised pentagon and the locator pin can help the dental model fit more easily into place.

[0045] In some examples, the locator plate has raised letters spaced apart from the raised pentagons, as shown in Figure 5. The raised letters may include a product identifier, case identifier, batch identifier, or another type of code used in downstream processing and manufacturing steps during the aligner manufacturing process.

[0046] In some instances, the locator plate further comprises a dental model attached to the raised pentagons and locator pins to form the dental aligner. In some instances, as shown in Figures 1-3, the locator plate further comprises a polymer sheet stretched over the dental model.

[0047] Specifically, FIG. 1 shows a polymeric material 101 thermoformed with a dental model 102 attached to a locator plate (not shown) in accordance with the present technique.

[0048] FIG. 2 provides a side view of the polymeric material 101 after it has been thermoformed with the dental model 102 .

[0049] FIG. 3 provides another top view of the polymer material 101 after it has been thermoformed with the dental model 102 .

[0050] 1-3, the drawings show the aligner still attached to the thermoformed product. That is, the locator plate has been removed, but the dental model 102 is still connected to the thermoformed sheet. Furthermore, before finishing operations (e.g., trimming, deburring, polishing, etc.) can be performed and before the final appliance (i.e., the aligner) is ready for use with a particular patient (i.e., the patient corresponding to the attached model), the thermoformed polymeric material must be cut from the sheet 101 and the dental model removed.

[0051] As is apparent from Figures 1 to 3, the polymer material is a thin thermoforming material. The thickness of the polymer material is not particularly limited, but it must be thick enough to be thermoformed around a dental model. Preferably, the thickness of the polymer material is less than 5 mm. More preferably, the thickness of the polymer material may be about 0.05 to about 5 mm.

[0052] 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.

[0053] The polymeric material 101 may include a multilayer polymeric material such as those described in, for example, 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 by reference in their entireties.

[0054] When the thermoforming material is exposed to heat, the material becomes more flexible, which allows the material to take on the shape of the imprint when molded and the appropriate pressure is applied.

[0055] However, it can be difficult to consistently and securely secure the 3D model during thermoforming. This technology solves this problem by developing a unique locator plate with locator features designed to help reliably locate and mate with the dental model for optimal thermoforming.

[0056] FIG. 4 shows 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. As described above and shown in FIGS. 1-3, the locator tab can be positioned within the dental arch and formed during the 3D printing process. In this embodiment, the locator tab 401 includes a pentagonal cutout 402 shaped to fit around a raised pentagon and a pin notch 403 shaped to fit around a locator pin. After trying various shapes, a pentagonal shape with a rectangular base and an isosceles triangular top demonstrated the best fit and alignment accuracy when mating the dental model with the locator plate. FIG. 4 also shows the pin notch 403, which aids in identifying and positioning the dental model to ensure excellent alignment. In FIG. 4, both the pin notch 403 and the pentagonal cutout 402 are chamfered. The chamfers make it easier for the locator plate to fit onto the dental model, reducing the chance of flash or excess 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 aid in alignment.

[0057] FIG. 5 shows another top perspective view of a locator tab 501 having a pentagonal polygonal cutout 502 with a rectangular base and an isosceles triangular top, and a pin notch 503 to assist in locating and positioning the dental model. FIG. 5 also shows alphanumeric characters 504 that may be presented at various locations on the locator tab 501. The characters are preferably in the form of raised letters and are spaced from the pentagonal cutout 502. In FIG. 5, the alphanumeric characters 504 are presented at three different locations on the locator tab 501 around the pentagonal cutout 502. The alphanumeric characters are used to identify and match specific 3D models. For example, a computer with a detector (e.g., using an optical character recognition camera) can scan the locator tab, read the characters, and match the dental model based on the character instructions, further streamlining the thermoforming process.

[0058] In one example, the alphanumeric characters represent a case number and / or step / architecture identifier, which may be in the form of an encrypted hexadecimal code. In some embodiments, rather than raising the letters, the letters may be cut through the entire model, allowing for more accurate readings from an optical character recognition camera. In a preferred embodiment, the length of the raised text is at least 1 mm, which overcomes potential issues in 3D printing. In an alternative embodiment, the letters are cut completely through the thickness of the locating tab. Cutting out the letters can further reduce the amount of material required during the 3D printing process.

[0059] The distance between the arch and the locator tab can vary because each arch has a unique anatomical shape. Thermoforming digital software, combined with the lettering, is used to determine the distance for each arch. Based on the arch's known location, the software ensures that the lettering is as indicated when merging one or more locating features with the arch.

[0060] 6-10 show various exemplary locator plate designs having locator features that are used to locate and secure to the dental model.

[0061] FIG. 6 shows a top perspective view of a locator plate, which includes a raised, chamfered pentagon 602 extending from the surface of the locator plate 601 and having a rectangular base and an isosceles triangular top, with the raised pentagon located in the center of the locator plate. Adjacent to the pentagon, a locator pin 603 is spaced from the raised pentagon and extends from the surface of the locator plate. Locator cones 604 are spaced from the raised pentagon and locator pins in a triangular arrangement, and mounting holes 605 are spaced from the raised pentagon and locator pins 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 an assembly line manufacturing process. The locator cones 604 are another locator feature that aids in positioning the locator plate relative to the dental model. The locator plate also has smaller holes 606, which allow air that may be trapped between the thermoforming material and the locator plate to escape during the thermoforming process, allowing for a tighter fit. In some embodiments, a vacuum system can be incorporated into the thermoforming system, which can provide suction through the smaller holes 606 to help hold the polymer material firmly to the locator plate 601. While only a few sides of the raised pentagon 602 are shown as chamfered in FIG. 6, many or few edges of the raised pentagon can be chamfered to aid in positioning the dental model on the locator plate 601. In some embodiments, the locator pin 603 can also have a chamfered top surface.

[0062] 7 shows a three-dimensional perspective view of the locator plate shown in FIG. 7 , which includes a raised chamfered pentagon 704 extending from the surface of the locator plate 701 and having a rectangular base and an isosceles triangular top, the raised pentagon being located in the center of the locator plate; a locator pin 705 spaced from the raised pentagon and extending from the surface of the locator plate; a locator cone 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 attach the locator plate 701 to various components during an assembly line manufacturing process. The smaller holes and grooves 706 allow air that may be trapped between the thermoforming material to escape during the thermoforming process. In some embodiments, a vacuum system can provide suction through the smaller holes 706 to help hold the polymer material firmly to the locator plate 701 .

[0063] Preferably, the locator cones 703 can be conical depressions in the locator plate 701, arranged as three cones spaced apart in a triangular configuration, as shown in Figures 6 and 7. During the thermoforming process, portions of the polymer material can be thermoformed into the locator cones 703, resulting in three thermoformed features in the polymer material (examples of these features can be seen in Figures 1 and 3). In some embodiments, these thermoformed cones can help orient the aligner material and dental model during downstream processes such as laser marking.

[0064] 8 shows a top perspective view focusing on raised polygon 801 and locator pin 802. Polygon 802 is preferably compact enough to fit inside all human dental arches and is chamfered for better fit and to avoid fit-to-dental model issues arising from 3D printing imperfections. The polygon cutout is preferably robust enough not to be damaged or broken during processing. Additional advantages of the polygon include its ease of manufacture, fast product orientation, easy fit-to-fit, and sufficient surface area to prevent part rotation.

[0065] In a preferred example, the polygon is a pentagon, which is useful in that it best meets the above criteria. In a more preferred example, the pentagon has a substantially rectangular, slightly rounded base and an isosceles triangular top, with the raised pentagon located in the center of the locator plate. The points at one end are easy to align, allowing for ergonomic and self-aligning back and forth loading, and the flat surface of the rectangular portion helps the pentagon prevent the part from rotating. In some embodiments, the points of the raised polygon 801 can be trimmed or cut out to further aid in mating the dental model with the locator plate, as shown in FIG. 8.

[0066] The number of locator features is not limited. In an alternative example, the locator plate has multiple polygonal notches. In another example, additional locator notches, such as additional locator pins, may be used and optimized based on the particular design of the thermoforming system being used.

[0067] In one example, digital software is used to determine the distance to each arch. The software can help keep track of where the arches are and ensure all text is displayed when merging the locating feature with the arches.

[0068] The letters may include the case number and step / arch identifier on the edge of the polygon cutout. In one example, the letters are encrypted hexadecimal codes. The letters may be at the base of the polygon (e.g., pentagon) and cut throughout the model, allowing for more accurate readings from an optical character recognition camera.

[0069] Any suitable length of raised text from the locator tab may be used. In a preferred example, the raised text may be at least 1 mm. In a preferred example, the cut-out text is cut completely through the thickness of the locator plate.

[0070] The raised polygon, locator pin, and / or locator plate may be chamfered. Chamfering advantageously allows for easier mating. Chamfering also advantageously helps reduce the possibility of any flashing or excess material from the 3D printing process preventing the parts from mating properly 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.

[0071] The locator plate may include one or more grooves and / or holes that allow the escape of air that may be trapped between the film and the plate during the thermoforming process. These holes may also be used in conjunction with a vacuum system to help hold the polymeric material firmly to the locator plate.

[0072] In a preferred example, the locator pins are spaced from the raised polygon. Spacing the pins from the polygon advantageously improves the locating mechanism(s) for keeping the arch oriented in a precise location. Spacing the locator mechanism(s) apart advantageously minimizes potential variations in the 3D arch dimensions that affect the thermoforming process. 3D printed parts often have some dimensional variation from part to part based on the accuracy of the printer. Additionally, the degree to which the 3D arch model is properly located impacts the accuracy of laser marking and robotic trimming.

[0073] 9 shows a top perspective view of the bottom of the same locator plate. Mounting holes 901 extend throughout the entire locator plate and can be arranged in any manner, preferably in a square arrangement. Smaller holes 902 and grooves 903 allow air to escape that may be trapped between the thermoforming material during the thermoforming process. Holes 902 and grooves 903 can also be used with a vacuum system to provide suction to help hold the polymer material firmly to the locator plate. The diameter of smaller holes 902 is not particularly limited. In a preferred embodiment, the smaller holes have a diameter of approximately 0.7 mm.

[0074] Figure 10 shows a three-dimensional perspective view of the bottom of the same locator plate. The mounting holes in Figure 10 are arranged in a square configuration, but the location of the mounting holes may depend on the thermoforming system. The grooves allow air that may be trapped between the thermoforming material to escape during the thermoforming process and are not limited in size.

[0075] The present technology further relates to methods for thermoforming aligners.

[0076] Generally, the methods of the present technology feature the use of locator plates and dental models to form specific, customized patient-specific aligners. The methods of the present technology may include the use of locator plates. As a result of incorporating the locator plates, the benefits of thermoforming are achieved, including superior fit and accuracy relative to the dental models.

[0077] In one embodiment, the method of the present technology includes six steps, as demonstrated in the flowchart of FIG.

[0078] The method begins by preparing a dental model for thermoforming. The dental model may be created by printing a 3D model (1103). This model may include a positive model of the dental arch and 3D printed locator tabs. The location of the locator tabs is not limited, but the locator tabs match each of the locator cutouts. In one embodiment, the locator tabs are preferably positioned inside the dental arch. The printing may include printing the edges of the polygonal cutouts with the 3D printed tabs and printing the boundaries of the pin notches within the 3D printed locator tabs. These features are printed to match and align with the locator plate with each of the cutouts in the features.

[0079] Next, a locator plate having locator features described herein is provided to secure 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, which aid in positioning and securing to the 3D model. The locator plate may also include a locator cone, which is a concave conical depression in the locator plate that further aids in precisely aligning the locator plate.

[0080] The 3D dental model is then secured to the locator plate by positioning locator features within each of the cutouts (1107). In a preferred example, the securing step includes positioning raised polygons within the polygon cutouts and positioning locator pins within the pin cutouts. The locator features of the locator plate ensure a consistent and secure fit with the dental model during the thermoforming process. Additionally, the 3D model can be moved to the proper position for thermoforming by repositioning the locator plate.

[0081] Once the locator plate is secured to the dental model and in the proper position, a thermoforming material may be thermoformed onto the dental model 1109. The thermoforming material is preferably a polymer / thermoplastic sheet or film that is biocompatible and moldable onto the dental model when sufficient heat and / or pressure is applied.

[0082] The above method may have the following additional exemplary features.

[0083] In this example method, the raised polygon has a particular shape that helps ensure a secure fit. For example, the raised polygon of the locator plate may have an apex directed toward the incisal edge of the dental arch, which indicates the proper orientation of the 3D dental model relative to the raised polygon of the locator plate.

[0084] In this example method, the raised polygon of the locator plate and the polygonal cutout in the 3D printed locator tab are pentagonal, which is generally optimal for securing dental arches.

[0085] Additional features of the locator plate in this method include a raised polygon and three recessed locator cones formed in the surface of the locator plate from which the locator pins extend.

[0086] In some examples of the method, the recessed locator cones are positioned in a triangular arrangement relative to the raised polygon. The triangular arrangement of the locator cones ensures proper orientation of the locator plate.

[0087] The locator cone may include a thermoformed portion that aids in securing the dental model. Thus, in some examples of the present methods, thermoforming the polymer sheet further includes thermoforming a portion of the polymer sheet within the concave locator cone. Furthermore, the triangular arrangement of the concave locator cone, when transferred to the thermoformed polymer sheet, may indicate an orientation of the thermoformed polymer sheet. For example, the orientation of the triangular arrangement of the concave locator cone may have a specific location relative to the incision in the dental arch model. In such embodiments, knowing the position of the locator cone may indicate the position of the dental arch model.

[0088] The present technology is further directed to a system for thermoforming an orthodontic aligner having a raised polygon and locator pins extending from a surface of a locator plate. The thermoforming system includes the above-described three-dimensional dental model and a locator plate to manufacture an aligner made from a thermoformable material.

[0089] In addition to the method, the present technology includes embodiments of a thermoforming system that utilizes a locator plate.

[0090] Specifically, the system includes a 3D dental model, which includes a positive model of a dental arch and a 3D printed locator tab positioned within 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.

[0091] The example system also includes a heat source for thermoforming a polymer sheet onto the 3D dental model once secured to the locator plate. The heat source must heat the thermoforming material sufficiently so that the material will form onto the dental model. The temperature to which the heat is applied depends on the desired thermoforming material.

[0092] In some examples of the system, the system includes printing a 3D dental model that defines edges of polygonal cutouts in the 3D printed locator tabs and boundaries of pin notches in the 3D printed locator tabs.

[0093] In an additional example of the system, the 3D dental model can be mated with a locator plate by positioning the raised polygon within the polygon cutout and the locator pin within the pin cutout. For example, a locator mechanism including a raised polygon, locator pin cutout, and locator cone optimizes the thermoforming process by precisely orienting the locator plate relative to the dental model for a secure fit when the thermoforming material is heated and pressed onto the dental model.

[0094] In some example systems, the 3D printed locator tabs include cut-out or raised letters positioned along one or more edges of the polygonal cutout. In a preferred example, the letters are in the form of a hexadecimal code and may be cut through the entire locator plate. The letters aid in identification and command to the thermoforming system using any suitable detector, such as a camera with optical character recognition software.

[0095] For identification purposes, the system further includes a camera for viewing and identifying notched or raised characters positioned along one or more edges of the polygonal notch.

[0096] With respect to the locator plate of the system, in some examples, the locator plate further defines a raised polygon and three recessed locator cones as locator features formed within the surface of the locator plate from which the locator pins extend, the recessed locator cones being positioned in a triangular arrangement relative to the raised polygon. When transferred to the thermoformed polymer sheet, the triangular arrangement of the recessed locator cones is useful for indicating the orientation of the thermoformed polymer sheet.

[0097] Specific embodiments and methods for securing a thermoformed model are disclosed. However, it will be apparent to those skilled in the art that many more modifications beyond those already described are possible without departing from the inventive concepts herein. Accordingly, the subject matter of the invention should not be limited except within the spirit of the present disclosure. Moreover, in interpreting this disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted to refer to elements, components, or steps in a non-exclusive manner, indicating that the referenced element, component, or step may be present, utilized, or combined with other elements, components, or steps not expressly referenced.

Claims

1. a locator plate for receiving and securing an individually unique dental model, 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 centrally located on the locator plate; a locator pin spaced from the raised pentagon, the locator pin extending from the surface of the locator plate; optionally, a first locator cone, a second locator cone, and a third locator cone spaced apart from said raised pentagon and said locator pin in a triangular arrangement; The locator plate.

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

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

4. 10. The plate of claim 1, further comprising a dental model attached to the raised pentagons and locator pins to form dental aligners.

5. The locator plate of claim 4 further comprising a polymer sheet stretched over the dental model.

6. 1. A method of thermoforming a dental aligner, comprising: printing a 3D dental model including a positive model of a dental arch and a 3D printed locator tab positioned within the dental arch, wherein printing the 3D dental model includes: printing edges of a polygonal cutout in the 3D printed locator tab; printing a boundary of a polygonal cutout in the 3D printed locator tab; providing a locator plate having a raised polygonal shape and a locator pin extending from a surface of the locator plate; Fixing the 3D dental model to the locator plate by positioning the raised polygon within the polygon cutout and the locator pin within the pin cutout; thermoforming a polymer sheet onto the dental model secured to the locator plate; The method comprising:

7. The method of claim 6 , further comprising moving the 3D model to an appropriate position for thermoforming by repositioning the locator plate.

8. 7. The method of claim 6, wherein the raised polygon of the locator plate has an apex directed toward the incisal edge of the dental arch, the apex indicating the 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. Printing the 3D dental model may further comprise: The method of claim 6 , comprising 3D printing cutout letter edges positioned along one or more edges of the polygonal cutout.

11. Printing the 3D dental model may further comprise: The method of claim 6 , comprising 3D printing polygonal characters positioned along one or more edges of the polygonal cutout.

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

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

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

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

16. 1. A system for thermoforming orthodontic aligners, comprising:

1. A 3D dental model comprising a positive model of a dental arch and 3D printed locator tabs positioned within the dental arch, printing the 3D dental model defines edges of polygonal cutouts in the 3D printed locator tabs and boundaries of pin notches in the 3D printed locator tabs; the 3D dental model mates with the locator plate by positioning the raised polygon in the polygon cutout and the locator pin in the pin cutout; a heat source for thermoforming a polymer sheet onto the 3D dental model when secured to the locator plate; The system comprising:

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

18. 20. The system of claim 17, further comprising a camera for viewing and identifying the cut-out or raised characters positioned along one or more edges of the polygonal cut-out.

19. 17. The system of claim 16, wherein the locator plate further defines three recessed locator cones formed in a surface of the locator plate from which the raised polygon and locator pins extend, the recessed locator cones being positioned in a triangular arrangement with respect to the raised polygon.

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

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