Dental implant with crown features and systems, devices and methods for designing and fabricating the same - Patents.com

Abstract

The root analog dental implant includes one or more coronal grooves sized, shaped, and / or configured to correspond to the size, shape, and / or location of the bone crest of the extracted tooth that the root analog dental implant is designed and manufactured to replace. The coronal grooves may be configured to engage the bone of the alveolar socket to enhance engagement between the root analog dental implant and the alveolar socket, particularly after placement of the root analog dental implant within the alveolar socket site and prior to osseointegration of the root analog dental implant with the alveolar socket. This promotes stability of the root analog dental implant within the alveolar socket site immediately after insertion, thereby reducing migration of the root analog dental implant within the alveolar socket site, reducing the likelihood of foreign material, such as bacteria or food, entering the alveolar socket site, and / or reducing the risk of implant fracture and jawbone injury.

Description

[Technical Field]

[0001] Related Applications This patent application is an international (PCT) patent application claiming priority to U.S. Provisional Application No. 63 / 436,093, filed December 29, 2022, and entitled "Dental Implants with Coronal Features and Systems, Devices, And Methods for Designing and Manufacturing Same," which is incorporated herein in its entirety.

[0002] The present invention relates generally to the field of dentistry, and more particularly to the field of dental implants. The present invention further relates to the field of using computer-aided design and / or additive manufacturing techniques to design and manufacture dental implants. [Background technology]

[0003] Historically, conventional dental implants have been placed into the site vacated by the extracted tooth after a lengthy healing period following the initial extraction. During this healing period, the bone structure of the tooth alveolar socket (hereinafter referred to as the "alveolar socket") is resorbed by the body and replaced with a layer of bone and soft tissue covering the extraction site. These conventional dental implants are provided in standard shapes and sizes, and a drill must be used to create an appropriately sized hole in the healed bone to accommodate the dental implant (i.e., osteotomy). Unfortunately, the natural hard and soft tissues surrounding the alveolar socket are not supported during this drilling process, often resulting in bone and gum line defects that commonly affect the aesthetic and functional aspects of the gum line. Furthermore, this methodology requires placement of the dental implant into the soft medullary bone, which requires a significant amount of time for the soft medullary bone to fully integrate with the dental implant (i.e., osseointegration) and provide the strength and stability required for normal function. Conventional dental implant placement can be achieved by screwing or press-fitting the dental implant into a drilled bone incision. After osseointegration, a permanent crown is attached to the dental implant via an attachable abutment. Summary of the Invention [Problem to be solved by the invention]

[0004] This methodology can require long waiting and healing times between extraction of the damaged tooth, performance of the osteotomy, placement of the dental implant, and placement of the permanent crown on the patient. Also, nerve damage is an inherent risk associated with the required osteotomy drilling. [Means for solving the problem]

[0005] Disclosed herein are root analog dental implants and methods for designing and manufacturing the same. The root analog dental implants can be designed using information such as three-dimensional scans, X-rays, intraoral scans, and CT scans of the patient's teeth and / or mouth before and / or after the extraction of natural teeth. In many cases, the root analog dental implants designed and disclosed herein have a monolithic structure and can be manufactured using additive manufacturing processes, for example, using a set of design and / or manufacturing instructions developed using a three-dimensional modeling and implant design process, for example, as disclosed herein. The external shape of the root analog dental implants disclosed herein can correspond to the size, shape, and / or configuration of the tooth and / or alveolar socket before or after the extraction.

[0006] The root analog dental implants disclosed herein are configured to replace a tooth that has been extracted from a patient's alveolar socket, which may have a bone crest line corresponding to where the top of the patient's jawbone meets the tooth prior to extraction, and a gingival layer (i.e., gums) that resides on the outer surface of the jawbone.

[0007] In some embodiments, the root analog dental implants disclosed herein may include a root portion configured to be placed in and / or occupy a space within an alveolar socket from which a tooth has been extracted. The alveolar socket may be unmodified and / or slightly modified prior to placing the root portion therein. The root analog dental implants disclosed herein may also include an exposed portion positioned and configured to abut the border of the root portion of the root analog dental implant and to reside at least partially within the gingiva surrounding the alveolar socket. The root portion may transition to the exposed portion along a root boundary located between the root portion and the exposed portion. The shape, contour, curvature, and / or position of the root boundary, or a portion thereof, may correspond to, match, and / or adapt to the shape, position, and / or curvature of the bone ridge surrounding the tooth prior to extraction (e.g., where the tooth emerges from the jawbone). The location (e.g., vertical placement) of the root boundary may depend on the clinician, design, and / or patient preferences and / or characteristics when designing, for example, to have the root boundary at or below the bony ridge of the patient's alveolar socket. In some embodiments, the root analog dental implants disclosed herein may further include an abutment positioned above (or below, depending on orientation) the exposed portion. In some embodiments, the root analog dental implants disclosed herein may have an external shape corresponding to the shape of the alveolar socket and / or the extracted tooth and / or root, and / or may include only one part. Sometimes, the root analog dental implants disclosed herein may be manufactured using additive manufacturing processes.

[0008] In many embodiments, the root analog dental implants disclosed herein may include one or more coronal grooves circumferentially surrounding the coronal portion of the root portion of the root analog dental implant. The size, shape, curvature, and / or location of the coronal grooves may correspond to the size, shape, curvature, and / or location of the root border and / or the bone ridge, respectively. The distance between each of the multiple coronal grooves may be the same or different. Sometimes, the number of coronal grooves included in the multiple coronal grooves depends on the clinician's preference and / or the patient's characteristics or preferences. Additionally or alternatively, the number of coronal grooves included in the multiple coronal grooves may depend on the patient's characteristics, the aesthetic characteristics of the root analog dental implant, the clinician's preference, the tooth characteristics, the tooth position, and / or the characteristics of the alveolar socket. For example, if a patient's characteristics include low bone density surrounding the alveolar socket, the number of coronal grooves included in the multiple coronal grooves may be greater than the standard number of coronal grooves.

[0009] In some embodiments, the root analog dental implant can include a porous surface that can be disposed, for example, on the diaphyseal and apical portions of the root portion. Additionally or alternatively, the root portion can include a support structure, such as a post.

[0010] Additionally or alternatively, the root portion of the root analog dental implants disclosed herein may include one or more of an extension, a tapered horizontally oriented coronal feature, a horizontally oriented coronal feature, a vertically oriented coronal feature, an array of tapered horizontally oriented coronal features, an array of horizontally oriented coronal features, and an array of vertically oriented coronal features.

[0011] In some embodiments, a root analog dental implant disclosed herein can be designed by receiving the size, shape, and bony crest characteristics of an extracted tooth, using the bony crest characteristics to determine the shape of a root boundary of a root portion of the root analog dental implant, and using the received size, shape, and bony crest characteristics of the extracted tooth to prepare a model of the extracted tooth. The model can include a root portion and an exposed portion configured to abut the root boundary of the root portion. A set of instructions for fabricating the root analog dental implant based on the model can then be generated and provided to a root analog dental implant manufacturing machine, which can be an additive manufacturing machine such as a three-dimensional printer. In some embodiments, the design of a root analog dental implant disclosed herein can include adding a coronal groove to the root portion of the model. The shape of the coronal groove can correspond to the root boundary.

[0012] In some embodiments, designing a root analog dental implant disclosed herein may further include receiving one or more of patient characteristics, aesthetic features of the root analog dental implant (e.g., the position of the root portion of the root analog dental implant relative to the gingiva surrounding the alveolar socket from which the tooth was extracted), clinician preferences, characteristics of the extracted tooth, and characteristics of the alveolar socket from which the extracted tooth was extracted (e.g., bone thickness and bone density), and a model may be prepared using the one or more patient characteristics, clinician preferences, tooth characteristics, and / or alveolar socket characteristics.

[0013] Additionally or alternatively, in some embodiments, the root analog dental implant disclosed herein may include one or more coronal grooves circumferentially surrounding the coronal portion of the root portion of the root analog dental implant (e.g., a portion of the root analog dental implant configured to be placed in an alveolar socket where a tooth has been extracted), and the curvature of the one or more coronal grooves may correspond to the curvature of the bone ridge. When the root analog dental implant includes multiple coronal grooves, the multiple coronal grooves may be arranged along the length in the coronal direction. In many embodiments, the shape or curvature of each coronal groove of the multiple coronal grooves will be the same, but it may be adjusted to accommodate variations in the coronal section along its length (e.g., horizontal cross-sectional shape, diameter, horizontal cross-sectional area, etc.). In some embodiments, the distance between some or all of the multiple coronal grooves may be the same (e.g., evenly spaced). Additionally or alternatively, the distance between some or all of the multiple coronal grooves may vary along the length of the coronal portion (e.g., not evenly spaced).

[0014] In some embodiments, the number, size, shape, position, and / or characteristics of one or more of the plurality of coronal grooves may depend on, for example, clinician preferences, patient characteristics, technical characteristics (e.g., design limitations or materials used to manufacture the root analog dental implant), aesthetic characteristics of the root analog dental implant and / or crown to be placed on the root analog dental implant, tooth characteristics, tooth position, and alveolar socket characteristics (e.g., bone density, type, and / or thickness). For example, if a patient characteristic is that the bone density surrounding the alveolar socket is low, the number of coronal grooves included in the plurality of coronal grooves may be adjusted accordingly in response to the patient's low bone density (e.g., increased from a baseline number of five coronal grooves to, for example, seven coronal grooves).

[0015] In some embodiments, a portion of the root portion of the root analog dental implant may include a porous surface configured to promote osseointegration between, for example, the root analog dental implant and the alveolar socket. The porous surface may be disposed on the diaphyseal and apical portions of the root analog dental implant.

[0016] In some embodiments, the root analog dental implants disclosed herein may include one or more support structures, such as posts, configured and / or disposed within and / or on the root analog dental implants to increase their mechanical and / or structural strength and / or integrity and / or help the root analog dental implants withstand forces exerted by the patient due to, for example, chewing, grinding, and / or bruxism.

[0017] In some embodiments, the root analog dental implants disclosed herein may include an exposed portion, a root border disposed between the exposed portion and the root portion, and an abutment. The exposed portion may be disposed adjacent to the coronal portion and may be sized, shaped, and configured to reside within the patient's gingiva, most often below the top or crest of the gingiva (i.e., the gingival margin), when the root analog dental implant is placed in the alveolar socket. In some embodiments, the root border may be placed below the bone crest (e.g., within the alveolar socket), so that, for example, even if some bone loss and / or resorption occurs around the top of the alveolar socket, the root border remains below the bone crest. In some embodiments, the shape of the root border may correspond to (e.g., mimic or trace) the shape of the coronal sulcus. Additionally or alternatively, the size, shape, and / or configuration of the exposed portion, root border, and / or abutment may depend, for example, on clinician preferences, technical features, and / or patient characteristics, as disclosed herein. In some embodiments, the shape of the coronal groove or grooves may correspond to the shape of the exposed portion, the bone crest, and / or the root border.

[0018] In some embodiments, the root analog dental implants disclosed herein may include one or more extensions, tapered horizontally oriented coronal features, horizontally oriented coronal features, vertically oriented coronal features, arrays of tapered horizontally oriented coronal features, arrays of horizontally oriented coronal features, and / or arrays of vertically oriented coronal features.

[0019] A method for designing a root analog dental implant as disclosed herein may include receiving the size, shape, and crest characteristics (e.g., location, shape, curvature, etc.) of an extracted tooth and preparing a model of the extracted tooth using the received size, shape, and crest characteristics of the extracted tooth. The model may include a modeled crest line that approximates the crest characteristics. One or more coronal grooves may then be added to the model. The one or more coronal grooves may have characteristics that correspond to the modeled crest line.

[0020] In some embodiments, one or more of patient characteristics, aesthetic features of the root analog dental implant (e.g., the position of the root portion of the root analog dental implant relative to the gingiva surrounding the alveolar socket from which the tooth was extracted), clinician preferences, characteristics of the extracted tooth, and characteristics of the alveolar socket from which the extracted tooth was extracted (e.g., bone thickness and bone density) may be received, and a model may be prepared using the one or more patient characteristics, clinician preferences, tooth characteristics, and / or alveolar socket characteristics.

[0021] Once the model is complete, it can be provided to a root analog dental implant manufacturing device, such as a three-dimensional printer or other additive manufacturing device.

[0022] The present invention and embodiments thereof are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a block diagram of a system that may be used to design and manufacture dental implants using additive manufacturing techniques, consistent with some embodiments of the present invention. [Figure 2] FIG. 1 is a block diagram of an exemplary processor-based system that may store data and / or execute instructions for the processes disclosed herein, consistent with some embodiments of the present invention. [Figure 3A]1 is a flowchart illustrating a first portion of a process for designing a dental implant, consistent with some embodiments of the present invention. [Figure 3B] 10 is a flowchart illustrating a second portion of a process for designing a dental implant, consistent with some embodiments of the present invention. [Figure 4A] 1 is a rendering of a buccal or lingual view of a tooth positioned in an alveolar socket prior to extraction, consistent with some embodiments of the present invention. [Figure 4B] 4B is a rendering of a mesial or distal view of a tooth positioned within the alveolar socket of FIG. 4A, consistent with certain embodiments of the present invention. [Figure 5A] 4B is a rendering of a buccal or lingual view of the tooth of FIG. 4A after extraction from the alveolar socket, consistent with certain embodiments of the present invention. [Figure 5B] 4B is a rendering of a mesial or distal view of the tooth of FIG. 4A after extraction from the alveolar socket, consistent with certain embodiments of the present invention. [Figure 6] FIG. 4B is a rendering of a buccal view of the primary model of the tooth of FIG. 4A with three cross sections superimposed, consistent with certain embodiments of the present invention. [Figure 7A] 7 is a rendering of a buccal-facing view of the primary model of FIG. 6 superimposed on a buccal-facing view of a fourth model of the tooth of FIG. 4A, consistent with some embodiments of the present invention. [Figure 7B] 7 is a rendering of a mesial or distal-facing view of the primary model of FIG. 6 superimposed on a mesial or distal-facing view of the fourth model of FIG. 4B, consistent with some embodiments of the present invention. [Figure 8A] 10 is a rendering of a portion of an exemplary first version of a sixth model of a dental implant showing the coronal and / or root interface, consistent with some embodiments of the present invention. [Figure 8B]10 is a rendering of a portion of an exemplary second version of a sixth model of a dental implant showing multiple coronal and / or root interface surfaces positioned along the length of the coronal portion of the root portion of the modeled dental implant, consistent with some embodiments of the present invention. [Figure 8C] 8B , a rendering of a portion of an exemplary third version of the sixth model showing multiple coronal grooves, each coronal groove of the multiple coronal grooves corresponding to a respective one of the multiple coronal and / or root interface surfaces shown in FIG. 8B , and a first coronal groove of the multiple coronal grooves may correspond to the model and / or the root boundary of a root analog dental implant manufactured using the model, consistent with some embodiments of the present invention. [Figure 8D] FIG. 8D is an enlarged view of a portion of the third version of the sixth model showing multiple coronary grooves of FIG. 8C, consistent with some embodiments of the present invention. [Figure 9A] 10 is a mesial or distal view of a first version of a seventh model of a dental implant including an exposed portion and an abutment, consistent with some embodiments of the present invention. [Figure 9B] FIG. 10 is a buccal or lingual view of a first version of the seventh model, consistent with some embodiments of the present invention. [Figure 10A] FIG. 10 is a buccal or lingual view of a second version of a seventh model of a dental implant, consistent with some embodiments of the present invention. [Figure 10B] FIG. 10 is a mesial or distal view of the second version of the seventh model, consistent with certain embodiments of the present invention. [Figure 11A] FIG. 10 is a mesial / distal view of an exemplary eighth model of a dental implant including an exemplary porous surface applied to the diaphyseal and apical portions of the modeled implant root, consistent with some embodiments of the present invention. [Figure 11B] FIG. 10 is a buccal / lingual view of an exemplary eighth model, consistent with certain embodiments of the present invention. [Figure 12A]FIG. 10 is a buccal / lingual view of an exemplary final model including an exemplary crown placed on an abutment of a root analog dental implant model, consistent with some embodiments of the present invention. [Figure 12B] FIG. 12B is a mesial / distal view of the exemplary final model of FIG. 12A, consistent with certain embodiments of the present invention. [Figure 12C] 12C is a mesial rendering of the final dental implant model of FIGS. 12A and 12B after the tooth has been extracted and placed within a CT scan of the alveolar socket surrounding the tooth in a subject's mouth, consistent with some embodiments of the present invention. [Figure 13A] FIG. 1 is an anterior view of a dental implant model including an array of coronal grooves and a plurality of additional horizontally oriented coronal features, consistent with some embodiments of the present invention. [Figure 13B] FIG. 13B is a side view of the dental implant model of FIG. 13A, consistent with some embodiments of the present invention. [Figure 14A] FIG. 12 is a mesial or distal side view of a dental implant model including an array of coronal grooves and a vertically oriented coronal feature, consistent with some embodiments of the present invention. [Figure 14B] FIG. 12 is a mesial or distal side view of a dental implant model including an array of coronal grooves and a plurality of vertically oriented coronal features, consistent with some embodiments of the present invention. [Figure 15A] FIG. 1 is a mesial or distal side view of a dental implant model including an array of coronal grooves and horizontally oriented coronal features positioned near the porous outer surface of the dental implant model, consistent with some embodiments of the present invention. [Figure 15B] FIG. 1 is a mesial or distal side view of a dental implant model including two horizontally oriented coronal features positioned near the porous outer surface of the dental implant model, consistent with some embodiments of the present invention. [Figure 16] FIG. 1 is a mesial or distal side view of a dental implant model including an array of coronal grooves and a tapered, horizontally oriented coronal feature positioned near the porous outer surface of the dental implant model, consistent with some embodiments of the present invention. [Figure 17] FIG. 1 is a mesial or distal side view of a dental implant model including an array of coronal grooves and an extended coronal feature positioned near the porous outer surface of the dental implant model, consistent with some embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0024] Throughout the drawings, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components, or portions of the illustrated embodiments. Moreover, while the invention will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments. It is intended that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the invention, as defined by the appended claims.

[0025] Root analog dental implants as disclosed herein can be designed using three-dimensional scans, CT scans, intraoral scans, and / or other images of the tooth and / or root before and / or after extraction.In order to preserve the shape and size information of the tooth to be extracted, it may be advantageous to atraumatically extract the tooth so that it is extracted from the jaw in one (or a few) pieces, and the pieces can then be scanned or otherwise imaged and used as models to design implants and / or implant components configured to replace the extracted tooth.In some cases, the implant design process can use three-dimensional scans or other images and information of the extracted tooth root as a basis for designing a three-dimensional model of a dental implant to replace the extracted tooth, which can then be fabricated using an additive manufacturing process such as three-dimensional printing. Once manufactured, a root analog dental implant designed using one or more processes described herein can be inserted directly into the original, unmodified alveolar socket from which the scanned and / or imaged tooth / root was extracted, before the jawbone has reformed itself to fill the vacant socket, as may occur between two and fourteen days after tooth extraction. Thus, the root analog dental implants described herein can be inserted into an unmodified, or in some cases, modified and / or slightly modified, socket, thereby eliminating the need to create an apical osteotomy as may be performed for an immediate implant, or to wait for bone to grow into the vacant socket and create a subsequent osteotomy to insert a conventional screw or press-fit a cylindrical implant.

[0026] Historically, dental implants have been manufactured from solid materials using subtractive means, or material removal, until the final desired shape is achieved. This method uses a mill, lathe, or other machine or method to remove material, such as titanium, from a stock piece (e.g., a cylinder or rod). These methods are advantageous, especially when large quantities of identical products are produced. However, one drawback to subtractive methods of manufacturing dental implants is the difficulty of adapting these processes to produce root-analog dental implants that are unique to a particular tooth, customized, or personalized, because adapting would require reconfiguring the subtractive implant-making equipment for each individual customized implant. This reconfiguration labor increases the time required to manufacture the implant and increases the cost of manufacturing the implant.

[0027] Another drawback to subtractive manufacturing of dental implants is the inherent limitation of features that can be included on the dental implant. For example, there are potentially desirable features (e.g., a porous exterior that promotes bone growth, or structural features that aid in the durability and / or strength of the implant) that are difficult or impossible to create by subtractive means due to the difficulty of carving out or tailoring features that may be internal to the dental implant (e.g., not on the surface).

[0028] Additive manufacturing techniques such as powder bed fusion (PBD), in which raw materials are in powder form and fused into a solid part using a highly focused heat source (e.g., a laser), provide an alternative means of forming dental implants that can be advantageous over subtractive manufacturing in situations where the dental implant design is customized for a particular patient and / or a particular tooth, or when there are desired characteristics for the dental implant that are difficult or impossible to achieve using subtractive manufacturing methods, for example, implants with different densities and / or different cross-sectional structures may be desired in some cases.

[0029] In some embodiments, one or more of the dental implants described herein may include one or more mechanical strength and / or support features, such as posts, rings, or helical elements, configured to provide mechanical and / or structural strength and / or support to the dental implant after insertion, such that the inserted dental implant can withstand various forces, such as forces and / or loads applied to the inserted dental implant from chewing and / or tearing, without fracture. In some embodiments, when the support feature is embodied as a post, for example, the post may extend perpendicularly from the axis and / or centerline of the dental implant body to the surface of the dental implant body. Additionally or alternatively, the support structure may extend from the center of the dental implant body toward the outer surface, but not to the surface of the dental implant body; in these embodiments, the support structure may be covered by another portion of the dental implant, such as a porous surface and / or a lattice structure as described herein.

[0030] Support features as disclosed herein can be designed and / or configured to provide strength and stability to the implant, for example, while under loads that are not coaxial with the root centerline and therefore create compressive loads and bending moments that can be applied to the implant during mastication. In some embodiments, the support feature design (e.g., size, shape, and location on or within the implant) can be configured to comply with the strength and load requirements for the dental implant, for example, using computer-aided design software and / or more processes described herein.

[0031] In some cases, the implant design process may incorporate numerous factors and / or features for the implant, which may be based on one or more characteristics of the extracted tooth, the jawbone, the alveolar socket, and / or the patient. For example, the design and / or configuration of the implant and / or support mechanism may be based on the root shape (curvature, length, amount of taper, etc.) of the tooth as it was placed in the patient's jaw, the jawbone characteristics adjacent to the extracted tooth, and / or how much shear / compression strain the implant is expected to experience over its lifetime. Other factors that may be incorporated into the implant design and / or configuration include the expected rate of osseointegration of the implant within the alveolar socket and / or whether and to what extent bone grafting may be required to ensure proper osseointegration. Additionally or alternatively, the implant and / or support structure design may be customized to accommodate one or more clinician preferences and / or to provide a design best suited to a particular case based, for example, on scientific evidence, clinical experience, and / or desired results. For example, if a dentist or oral surgeon has a particular preferred design for the implant and / or root configuration they work with, that preference may be incorporated into the design of the implant. In another example, if a clinician observes that a patient has brittle or relatively thin bone surrounding the alveolar socket where the implant will be placed, such observation may be taken into account in the design of the implant so that the implant fits properly within the alveolar socket and does not overstress certain areas of the bone surrounding the socket, which may reduce the likelihood of bone breakage or fracture caused by, for example, pressure exerted on the bone by the implant.Additionally or alternatively, dentists or clinicians may have different preferences regarding the surface texture of portions of the root analog implant (e.g., polished, highly polished, rough, finely textured, rough, etc.), the shape, size, and / or number of coronal grooves, the shape, size, position, and / or crown engagement mechanism of the abutment, and / or the shape, size, position, and / or surface texturing of the transgingival section of the root analog dental implant.

[0032] In some embodiments, the design and / or configuration of the support structure may be responsive to, for example, an analysis of the shape and / or size of the extracted tooth and / or root, as shown, for example, in a three-dimensional scan of the extracted root, an x-ray, an intraoral scan of the tooth and / or alveolar socket, and / or an external scan, such as a CT scan or an MRI scan.

[0033] The support structures embodied as struts may be of any cross-sectional size, shape, or combination of shapes, including, but not limited to, square, rectangular, star, hexagonal, circular, triangular, multiple curved extensions, and I-beam shapes. In some cases, the size and / or orientation of the support structure may vary along the length of the implant root section. For example, the support structure may be thinner near the apex of the root section and gradually increase in thickness to a maximum thickness at or near the coronal section. Additionally or alternatively, the dimensions (e.g., thickness, width, or height) of the support structure may be proportional to the overall size of the implant root section, such that as the cross-sectional area of ​​the root section decreases from the coronal section to the apical section, the dimensions of the support structure vary in size depending, for example, on the strength requirements of the implant root and / or the preferences of the clinician and / or user.

[0034] In embodiments in which both a support structure and a porous surface are used in the design of a root analog dental implant, the support structure can provide the microgeometry or surface texture of the implant. Sometimes, when the support structure extends to the outer surface of the implant, the surface of the posts that match the outer surface of the implant can include small or nano-surface features (e.g., indentations, ridges, or cross-hatching) that can be configured to provide a surface for bone growth. Sometimes, the posts can provide the macrogeometry, and the lattice and / or porous structure can provide the microgeometry, and additional, even smaller features, such as nano-surface treatments, spikes, and / or extensions, can be applied to and / or designed into one or more posts and / or portions of the lattice and / or porous structure. In some embodiments, the design of the support structure posts and / or lattice for the implant can depend on, for example, clinical considerations and / or preferences, tooth type, tooth position within the mouth, anatomical variations, patient preferences and / or characteristics, crown characteristics, tooth orientation, and / or extracted teeth and / or the characteristics of the teeth surrounding the implant.

[0035] Sometimes, the shape, size, orientation, and / or configuration of one or more support structures may depend, for example, on the characteristics of the extracted tooth root and / or the alveolar socket from which the tooth was extracted, and / or on where those support structures are located within the root analog implant. For example, in some cases, support structures located on the buccal and / or lingual sides of the outer surface of the root analog implant core may extend a relatively large lateral or vertical distance from the implant core and / or to the porous surface (i.e., which may be shallow) covering the core, providing greater mechanical strength in this embodiment. Additionally or alternatively, posts located on the mesial and / or distal sides of the root analog dental implant core may extend a relatively small lateral or vertical distance from the outer surface of the core, because in this embodiment, bending moments may be relatively small.

[0036] In some embodiments, the support structures may be evenly spaced around the circumference of the root analog dental implant core. Alternatively, the posts may be irregularly spaced around the circumference of the root analog dental implant core. In these cases, the placement of one or more support structures may depend, for example, on the characteristics of the tooth root and / or the root analog dental implant. For example, more support structures may be placed on the buccal and / or lingual side of the root analog dental implant than on the mesial and / or distal sides. This is because the buccal and / or lingual sides of the root analog dental implant require greater mechanical resistance to loads applied to the implant during function, for example, due to chewing, grinding, and / or bruxism. Placing more support structures on the buccal and / or lingual sides of the root analog dental implant may provide mechanical strength to the implant and / or aid in the distribution of forces along the buccal and / or lingual sides of the root analog dental implant.

[0037] In many cases, a primary requirement for dental implants is that they must withstand the forces exerted on them by chewing to ensure that they do not mechanically fail under expected maximum loads (tensile / compressive / shear strength) or cyclic loads over time (fatigue). This includes the maximum bite force from a single bite, as well as the cyclic forces of chewing repeated over the expected life of the dental implant. Typically, dental implant manufacturers test their products to ensure that the dental implants can withstand both maximum bite force and cyclic loads based on average and maximum forces over millions of cycles without failure.

[0038] Loads applied to a dental implant tend to be greatest at or near the top of the root portion of the dental implant (e.g., the portion of the dental implant corresponding to the coronal section) and least at or near the root portion or apex of the dental implant. For this reason, there is an opportunity to remove material or increase the porosity and / or thickness of the porous surface at or near the apex of the dental implant, as this would not contribute to the function or performance of the dental implant.

[0039] In some embodiments, the coronal grooves disclosed herein can be sized, positioned, and / or configured to increase static friction between the installed root analog dental implant and the alveolar socket, particularly after insertion and before osseointegration of the root analog dental implant. This can result in greater stability of the root analog dental implant during the first few weeks after placement into the alveolar socket, so that the root analog dental implant can remain stable within the alveolar socket during the healing / osseointegration process. Sometimes, multiple coronal grooves can be sized, positioned, and / or configured so that the coronal portions of the root analog dental implant do not apply equal force to corresponding portions of the alveolar socket, thereby reducing stress on portions of the alveolar socket and, for example, preventing fracture or resorption of corresponding bone when the root analog dental implant is placed within the alveolar socket.

[0040] Referring now to the figures, FIG. 1 is a block diagram of a system 100 that may be used to design and manufacture a root analog dental implant as described and illustrated herein using additive manufacturing techniques such as 3D laser printing. The system 100 may include a clinician device 110, one or more imaging devices 115, a communications network 120, a computer / processor / memory 125, a dental implant fabrication tool 130, and / or a three-dimensional scanner 135. One or more components of the system 100 may include and / or be communicatively coupled to a display device and / or a user input device (e.g., a keyboard, a speaker, a touch screen, etc.). The communications network 120 may be any network configured to facilitate communication between two or more components of the system 100. An exemplary communications network 120 includes the Internet.

[0041] The clinician device 110 may be any device, such as a computer, tablet computer, and / or smartphone, present in a clinic (e.g., a dental office) configured to communicate with one or more devices of the system 100. The clinician device 110 may be configured to communicate patient information and / or tooth extraction information, for example, to the computer / processor / memory 125. In some embodiments, the clinician device 110 may communicate with an imaging device 115, for example, to view or obtain information regarding one or more images, such as X-rays or scans, of the patient's mouth, jaw, and / or teeth. In some cases, the imaging device 115 may be present in the clinic. Additionally or alternatively, the imaging device 115 may be present in a separate facility (e.g., a hospital or medical clinic). Exemplary imaging devices 115 include, but are not limited to, X-ray machines, intraoral scanners, and CT scanning devices.

[0042] The computer / processor / memory 125 may be configured to design a dental implant that can be manufactured using additive manufacturing, for example, according to one or more of the methods disclosed herein. In some embodiments, the computer / processor / memory 125 may communicate with a processor-based system 200, such as that shown in FIG. 2 and described below, via, for example, the communications network 120. In some embodiments, the computer / processor / memory 125 may be distributed and / or reside in multiple pieces of hardware that communicate with each other via wired and / or wireless connections (e.g., the communications network 120). In some embodiments, the computer / processor / memory 125 may be configured as a deep neural network capable of performing one or more operations, for example, using artificial intelligence and / or machine learning.

[0043] The three-dimensional scanner 135 may be configured to scan the extracted tooth root in three dimensions and communicate the three-dimensional scan to the clinician device 110 and / or computer / processor / memory 125 via the communications network 120.

[0044] The dental implant fabrication tool 130 is configured to receive instructions for fabrication of one or more of the dental implants and / or dental implant components disclosed herein. The dental implant fabrication tool 130 may be, for example, an additive manufacturing tool and / or a set of tools such as a 3D printer, a computer-aided manufacturing (CAM) module, and / or a milling machine.

[0045] In some embodiments, not all components of system 100 may be co-located. For example, 3D scanner 135 may be located in a dental office and may communicate 3D scans of extracted tooth roots to other components of system 100 via communications network 120.

[0046] 2 provides an example of a processor-based system 200 that may store and / or execute instructions for one or more of the processes described herein. Processor-based system 200 may reside, for example, in clinician device 110 and / or computer / processor / memory 125. It should be noted that not all of the various processor-based systems that may be employed in accordance with embodiments of the present invention have all of the features of system 200. For example, a particular processor-based system may not include a display, because the display function may be provided by a client computer communicatively coupled to the processor-based system, or because the display function may be unnecessary. Such details are not important to the present invention.

[0047] System 200 includes a bus 103 or other communication mechanism for communicating information and a processor 104 coupled to bus 103 for processing information. System 200 also includes a main memory 106, such as a random access memory (RAM) or other dynamic storage device, coupled to bus 103 for storing information and instructions to be executed by processor 104. Main memory 106 may also be used to store temporary variables or other intermediate information during execution of instructions to be executed by processor 104. System 200 further includes a read-only memory (ROM) 108 or other static storage device coupled to bus 103 for storing static information and instructions for processor 104. Storage device 111, which may be one or more of a hard disk, flash memory-based storage medium, magnetic storage medium, optical storage medium (e.g., Blu-ray Disc, Digital Versatile Disc (DVD)-ROM), or any other storage medium readable by processor 104, is provided and coupled to bus 102 for storing information and instructions (e.g., an operating system, application programs, etc.).

[0048] System 200 may be coupled via bus 103 to a display 112, such as a flat panel display, for displaying information to a user. An input device 114, such as a keyboard including alphanumeric and other keys, may be coupled to bus 103 for communicating information and command selections to processor 104. Another type of user input device is a cursor control device 116, such as a mouse, trackball, or cursor direction keys, for communicating directional information and command selections to processor 104 and for controlling cursor movement on display 112. Other user interface devices, such as a microphone, speaker, etc., are not shown in detail but may be associated with receiving user input and / or presenting output.

[0049] The processes referred to herein may be implemented by processor 104 executing appropriate sequences of processor-readable instructions stored in main memory 106. Such instructions may be read into main memory 106 from another processor-readable medium, such as storage device 111, and execution of the sequences of instructions contained in main memory 106 causes processor 104 to perform the associated actions. In alternative embodiments, hardwired circuitry or firmware-controlled processing units (e.g., field programmable gate arrays) may be used in place of, or in combination with, processor 104 and its associated computer software instructions to implement the invention. Processor-readable instructions may be rendered in any computer language.

[0050] System 200 may also include a communications interface 118 coupled to bus 103. Communications interface 118 may provide a bidirectional data communications channel with a computer network, which in turn provides connectivity to the plasma processing system described above. For example, communications interface 118 may be a local area network (LAN) card for providing a data communications connection to a compatible LAN, which is itself communicatively coupled to other computer systems. The precise details of such communications paths are not important to the present invention. What is important is that system 200 can send and receive messages and data through communications interface 218, and thus communicate with other controllers, etc.

[0051] 3A and 3B provide a flowchart illustrating a process 300 for designing a root analog dental implant, such as the root analog dental implant described herein. Process 300 may be performed, for example, by a processor or computer executing a set of instructions stored in a memory (e.g., memory 106) in communication with a processor (e.g., computer / processor / memory 125 and / or processor 104). In some embodiments, process 300 may be performed using one or more specially designed and / or proprietary software packages configured to perform process 300 or portions thereof. In some cases, one or more steps of process 300 may be performed automatically, for example, through the execution of a machine learning process, e.g., the application of an algorithm developed via a machine learning process that analyzed data from multiple extracted dental roots, or the input of information into a deep neural network configured to perform one or more steps of process 300. Sometimes, one or more steps of process 300 may be performed via a distributed computing network and / or a local computer interfacing with a dental implant design professional. Additionally or alternatively, in some embodiments, one or more steps of process 300 may be performed using a computer-aided drawing software program. Figures 4A-17 provide a series of drawings illustrating an extracted tooth and a series of iterations on a model of a dental implant that may occur during the performance of a dental implant design process such as process 300, and will be discussed below with respect to exemplary relevant steps of process 300.

[0052] In step 305, information regarding the tooth to be extracted, the extracted tooth, the extracted root, and / or the patient from whom the tooth was extracted can be received, for example, by a processor-based system, which in some embodiments may include a processor configured to incorporate a computer-aided design (CAD) module, such as computer / processor / memory 125. In many cases, the information received in step 305 includes one or more two-dimensional or three-dimensional images and / or scans of the extracted root, the extracted root fragments, and / or the alveolar socket from which the tooth was extracted. This information may be received, for example, from / via an intraoral scanner, an X-ray image, a CT scan image, a three-dimensional scanner such as three-dimensional scanner 135, and / or a clinician device such as clinician device 110. Additionally or alternatively, the information received in step 305 may be a scan of the patient's jaw and teeth, such as a cone beam CT (CbCT), a scan of the tooth and / or root before or after extraction, and / or a scan of the patient's tooth / root and adjacent teeth and / or opposing dentition. These scans may be, for example, CT scans, X-rays, and / or intraoral scans. Additionally or alternatively, the information received in step 305 may be one or more patient characteristics, such as gender, age, bone health, expected healing rate, bone thickness, bone density, and / or aesthetic considerations.

[0053] The renderings in Figures 4A, 4B, 5A, and 5B provide examples of information that may be received in step 305. In particular, Figure 4A provides a rendering of a buccal view of a tooth 400 positioned in an alveolar socket prior to extraction, and Figure 4B provides a rendering of a mesial view of the tooth 400 positioned in the alveolar socket. The tooth 400 includes a bone portion 405 and a root 410 separated from each other by a bone crest 425 of a bone 420 forming the alveolar socket. Figures 4A and 4B also show the soft tissue or gums 417 positioned over the bone 420, the bone crest 425, and the surrounding tooth 400 and gums 417. Figure 5A provides a rendering of a buccal view of the tooth 400 after extraction from the bone 420 and alveolar socket, and Figure 5B provides a rendering of a mesial view of the tooth 400 extracted from the alveolar socket. 5A and 5B also provide a bone crest curve 427 and a gum curve 418. The bone crest curve 427 depicts where on the tooth 400 the bone crest 425 was prior to the extraction of the tooth 400 from the bone 420, and the gum curve 418 depicts where on the tooth 400 the gum margin 415 was prior to the extraction of the tooth 400 from the bone 420.

[0054] Optionally, in some embodiments, one or more patient characteristics (e.g., age, sex, bone quality, bone dimensions, bone density, health status, and / or whether the patient is immunocompromised) and / or clinician preferences (e.g., occlusal requirements, functional requirements, aesthetic requirements, and / or prosthetic requirements) may be received in step 305. These characteristics and / or preferences may be used to design the root analog dental implant model and / or its features in process 300. In one example of patient characteristics, if the patient has relatively low bone density, bone thickness, and / or bone quality, the root analog dental implant may be designed to exert relatively minimal force on the buccal and / or lingual surfaces of the alveolar socket when inserted therein.

[0055] The clinician's preferences that may be received in step 305 may be used, for example, to design an implant that can accommodate the clinician's preferences for inserting the implant and / or preferences for implant design, function, operation, durability, and / or aesthetics. Additionally or alternatively, the clinician's preferences may include preferences for the shape and / or design of the final root implant. In some embodiments, information from the clinician and / or dentist regarding the patient and / or the clinician's preferences may be received in step 305, for example, as part of a prescription for the implant. The prescription may also include, for example, aesthetic requirements for the patient and / or clinician's preferences for implant design, some examples of which are provided in the discussion of process 300 below.

[0056] Next, in step 310, a first model of the extracted tooth root may be generated. The first model may be a two-dimensional or three-dimensional rendering of the extracted tooth (e.g., extracted tooth 400) generated using the data received in step 305 and may closely or exactly match the size, shape, and / or dimensions of the extracted tooth, including the root and supraspinal portion. In some embodiments, performing step 310 may include determining the portion of the three-dimensional image and / or scan received in step 305 that relates to the crown and root of the extracted tooth; this determination may be made via analysis of the position and / or shape of ridges, such as ridge curve 425.

[0057] 6 provides a buccal view of an exemplary primary or first model 600 of tooth 400 that may be generated in step 310, for example, using information that may be received in step 305. First model 600 may be a two-dimensional or three-dimensional rendering of unmodified tooth 400 (i.e., a model that replicates the contours, dimensions, and / or shape of tooth 400). First model 600 includes a modeled crown 605 that corresponds to the size, position, and / or shape of crown 405, a modeled root 610 that corresponds to the size, position, and / or shape of root 410, and a modeled bone crest curve 625 that corresponds to the size, position, and / or shape of bone crest curve 425.

[0058] Optionally, in step 312, a preliminary design check may be performed to determine whether the extracted root is suitable for and / or compatible with implant design process 300. In some embodiments, step 312 may be performed by comparing a first model of the extracted root with one or more pre-generated and / or template implant designs and / or design envelopes for implants designed using process 300 to verify that parameters for designing an implant to replace the extracted tooth are compatible (e.g., fall within ranges) with the design parameters required for an implant designed using process 300. The design envelope parameters may include, for example, the length, width, circumference, shape, and / or angle of the root in one or more directions (e.g., mesial, distal, buccal, and / or lingual).

[0059] In step 315, the first model of the extracted tooth root of step 310 may be modified to remove any or all portions of the first model that are not related to the root (e.g., portions of the first model that correspond to crown 405), thereby generating a second or modified model of the root. In some embodiments, performance of step 315 may include removing irregularities in the shape of the three-dimensional model (e.g., tissue debris, irregularities on the tooth surface, hooked portions of the root, etc.) so that, for example, the root portion of the model has a smooth or nearly smooth outer surface prior to completion of the design process. Performance of step 315 may generate a second model of the tooth for use in designing a dental implant as described herein.

[0060] In step 320, aspects, sides, and / or portions of the second model may be identified and / or determined. In some embodiments, performing step 320 may include, for example, identifying the buccal, lingual, mesial, distal, coronal portion, diaphyseal portion, and / or apical / apical regions of the modified model of the tooth root.

[0061] Optionally, in step 325, the length of the second model of the root of step 315 (i.e., the distance from the bottom to the top of the root) may be adjusted, thereby generating a third model of the tooth for use in designing the dental implant. The adjustment performed in step 325 may include, for example, shortening the height of the modified model of the root by, for example, removing 0.15 mm to 0.8 mm from the edge of the model proximal to the bone crest curve 625. In some embodiments, performing step 325 may include determining expected changes in the shape and / or size (e.g., loss of depth and / or expansion of circumference) of the alveolar socket, which may be caused, for example, by bone loss and / or bone resorption due to the natural healing process when the body / alveolar socket recovers from tooth extraction and / or placement of a root analog dental implant as described herein. In some embodiments, the expected changes may be due, for example, to bone loss at the top or margins of the alveolar socket, which may be caused, for example, by the body's inflammatory response after root extraction. The size and shape of the root portion of the dental implant may be (e.g., shortened) depending on the expected change in size and / or shape of the alveolar socket. Sometimes, determining the expected change in size and / or shape of the alveolar socket following the healing process may depend, for example, on patient characteristics, tooth placement, jawbone characteristics, etc.

[0062] In step 330, a fourth model of the tooth for use in designing a dental implant may be generated by adjusting the size, cross-sectional area, and / or volume of the second (or, if step 325 is performed, third) model of the tooth root. Adjustments made in step 330 include, but are not limited to, reducing the width and / or cross-sectional diameter of the second (or third) model of the tooth root of step 315 or 325 by narrowing and / or reducing the width of the second (or third) model of the tooth root of step 315 or 325 by reducing the diameter and / or cross-sectional area of ​​the model in the buccal / lingual direction (e.g., by 0.01-0.7 mm). In some embodiments, this adjustment may be made by moving the buccal and / or lingual edges of the model of step 315 or 325 inward, e.g., by 0.01-0.7 mm along the length of the model, thereby reducing the overall volume, width, and / or cross-sectional area of ​​the tooth root model.

[0063] Additionally or alternatively, performing step 330 may include expanding the horizontal cross-sectional area or circumference of the mesial and / or distal sides (along their lengths) of the second or third model, thereby creating mesial and / or distal extensions. In these embodiments, the mesial and / or distal extensions may be configured to abut and / or press against the adjacent mesial and / or distal bone walls of the alveolar socket into which the implant designed via performing process 300 will be placed, thereby increasing the amount of friction and / or compression applied to the mesial and / or distal walls of the alveolar socket, which may act to initially hold the implant in place within the socket until, for example, osseointegration occurs. The external shape or contour of the mesial and / or distal extensions may have a curved and / or parabolic cross-section, such that the apex of the extension is located at or near the longitudinal center of the fourth model on the mesial and / or distal side. In some cases, the shape and / or size of the mesial and / or distal extensions may be mirror images of each other, while in other cases, the size and / or shape (e.g., apex location, curvature, etc.) may differ between the mesial and distal projections. An exemplary dimension for the width of the mesial and / or distal projection is 0.1-0.75 mm along the mesial and / or distal length of the model. In some cases, the width of the mesial and / or distal projection may vary along its length, such that the width of the mesial and / or distal projection is 0.05-0.2 mm in the cortical section of the base portion of the model, 0.02-0.3 mm in the diaphyseal section, and 0.01-0.35 mm in the apical section.

[0064] 7A and 7B provide renderings of an exemplary fourth model 700 having a modified root portion 710 that may be generated through performance of step 330, superimposed on the first model 600 of FIG. 6. In particular, FIG. 7A provides a rendering of a mesio-distal view of the first model 600 superimposed on a corresponding mesio-distal view of the fourth model 700 (shown in dashed lines). The distance between the outer contour of the first model 600 and the outer contour of the fourth model 700 represents the width of the mesial and / or distal prominence of the fourth model 700. FIG. 7A also shows first, second, and third crest curve points 730A, 730B, and 730C, respectively, on the first and fourth models, corresponding to where a crest curve 725 corresponding to bone crest curve 425 would be located on the mesial and / or distal sides of the fourth model 700 as shown in FIG. 7A.

[0065] 7B provides a rendering of the buccal / lingual view of first model 600 superimposed on the corresponding buccal / lingual view of fourth model 700 (shown in dashed lines). The distance between the contours of first model 600 and fourth model 700 represents the width of the buccal / lingual recess of fourth model 600. FIG. 7B also shows second, third, and fourth ridge curve points 730B, 730C, and 730D, respectively, on the first and fourth models, which correspond to where ridge curve 725 would be located on the buccal and / or lingual sides of fourth model 700 as shown in FIG. 7B.

[0066] In step 335, the exposed portion and abutment may be added to the fourth model, thereby creating a fifth model of the tooth to be used in designing the root analog dental implant. The exposed portion may be positioned between the abutment and root portion of the fourth model, with the root top configured to trace the separation between the exposed portion and root portion of the fifth model. The root top may be configured to reside below (e.g., 0.1-1.5 mm), on, and / or slightly above (e.g., 0.1-1 mm) the bone crest (e.g., modeled crest curve 725), and the exposed portion may be configured to reside adjacent to soft tissue or gingiva.

[0067] In some embodiments, the size (e.g., length, circumference, etc.) of the exposed portion and / or the location and / or shape of the upper root portion may depend on, for example, clinician and / or patient preference. For example, in some embodiments, the exposed portion may be relatively short and / or the upper root portion may be vertically offset from the bone crest such that it is positioned within the alveolar socket (i.e., below (for mandibular teeth) or above (for maxillary teeth) the bone crest or modeled crest curve 725) so that a root analog dental implant manufactured pursuant to performance of one or more steps of process 300 may remain below or above the bone crest line even after bone changes that may occur as part of the patient's healing process following extraction of natural teeth. In some cases, the size, shape, and / or configuration of the exposed portion may be narrowed or reduced circumferentially or preferentially to maintain the biological width of the patient's gingival tissue.

[0068] The abutment may extend above the exposed portion and be configured to cooperate with a crown or other covering, the bottom edge of which may be positioned slightly below the gum margin and extend above the gum.

[0069] In some embodiments, the size and / or shape of the abutment may be configured for cooperation with the crown so that the crown is securely attached to the abutment and the crown fits and / or cooperates properly with other teeth in the patient's mouth. Sometimes this may be accomplished, for example, through the use of information received in step 305 (e.g., pre-operative intraoral scans and / or CT scans of the patient's tooth to be extracted and surrounding teeth (e.g., height, width, ridge depth, angle, etc.)). In some cases, the abutment may be shaped as a pre-designed chamfer shape of appropriate size (e.g., cross-sectional area, height, etc.). In some embodiments, the height of the abutment may be selected using information provided by a dental professional (e.g., the dental professional who extracted the tooth and / or is tasked with inserting a root analog dental implant manufactured pursuant to execution of process 300, or the dental professional responsible for the placement of the crown) and / or received in step 305 (e.g., the height of the teeth adjacent to the extracted tooth, the chewing habits of the patient who had their tooth extracted, the strength or thickness of the bone that makes up the alveolar socket, and / or whether the patient has periodontal disease).

[0070] In step 340, one or more coronal grooves and / or features may be added to an upper section of the root portion of the fifth model, which may be proximate to modeled ridge curve 725, for example. Execution of step 340 may create a sixth model of the tooth for use in designing a root analog dental implant. The coronal grooves and / or features added via execution of step 340 may be configured and / or positioned to increase friction between a root analog dental implant fabricated using the sixth model and the surrounding bone of the alveolar socket upon insertion into the alveolar socket, for example, by engaging the bone (e.g., pressing into the bone) and / or providing a surface area onto which bone may grow during osteointegration of the root analog dental implant into the alveolar socket. Additionally or alternatively, the coronal grooves and / or features may be configured to inhibit the ingress of foreign bodies (e.g., fluids, solids, and / or bacteria) into the alveolar socket after bone growth into the coronal grooves and / or features of the root analog dental implant fabricated using the sixth model.

[0071] In some embodiments, one or more coronal grooves may have a shape and / or circumferential curvature similar to and / or mimicking the crest curve of the extracted tooth (e.g., modeled crest curves 725 and / or 625). An example of how step 340 may be performed according to this embodiment is depicted in FIGS. 8A-8E, where FIG. 8A provides an enlarged view of a portion of an exemplary first version of sixth model 801 showing crest contour 805 matching modeled crest curves 625 and / or 725 (not shown). The shape and / or curvature of crest contour 805 may be determined, for example, by using a computer-aided drawing (CAD) program or other software to create a curvature that intersects and / or overlaps with all or some points on the modeled crest curve. Additionally or alternatively, crest contour 805 may be a smoothed or normalized version of the shape and contour of modeled crest curves 625 and / or 725. In some embodiments, the bone crest contour 805 may be, correspond to, and / or define the shape, size, and / or configuration of the root boundary and / or transition point and / or line between the root portion of the sixth model 801 (e.g., the modified root portion 710) and the exposed portion 855.

[0072] Next, multiple coronary sulcus contours can be designed and positioned along the coronal portion of the sixth model (e.g., modified root portion 710). The shape, position, and / or size of the coronary sulcus contours can be similar to the shape, size, and / or position of the bone crest contour 805, for example, as shown in FIG. 8B, which provides a close-up view of a portion of an exemplary second version of the sixth model 802, including an array 820 of six coronary sulcus lines 810 (first coronary sulcus line 810A, second coronary sulcus line 810B, third coronary sulcus line 810C, fourth coronary sulcus line 810D, fifth coronary sulcus line 810E, and sixth coronary sulcus line 810F) positioned circumferentially along the vertical length of the modified root portion 710. The shape or curvature of each of the first coronal sulcus contour 810A through the sixth coronal sulcus contour 810F is based on the bone crest contour 805 shown in FIG. 8A, adjusted to fit the external shape of the modified root portion 710.

[0073] The first coronary groove line 810A through the sixth coronary groove line 810F can then be converted into modeled coronary grooves as shown in Figures 8C and 8D, which are cutaway and close-up views, respectively, of a portion of an exemplary third version of the sixth model 803, including an array 840 of six modeled coronary grooves whose shapes, sizes, and locations correspond to respective ones of the array 820 of coronary groove lines 810. For example, the size, shape, and position of the first modeled coronary groove 830A corresponds to the size, shape, and position of the first coronary groove contour 810A, the size, shape, and position of the second modeled coronary groove 830B corresponds to the size, shape, and position of the second coronary groove contour 810B, the size, shape, and position of the third modeled coronary groove 830C corresponds to the size, shape, and position of the third coronary groove contour 810C, the size, shape, and position of the fourth modeled coronary groove 830D corresponds to the size, shape, and position of the fourth coronary groove contour 810D, the size, shape, and position of the fifth modeled coronary groove 830E corresponds to the size, shape, and position of the fifth coronary groove contour 810E, and the size, shape, and position of the sixth modeled coronary groove 830F corresponds to the size, shape, and position of the sixth coronary groove contour 810F. Each of the first modeled coronal groove 830A through the sixth modeled coronal groove 830F is recessed and / or recessed into the outer surface of the modified root portion 710 and, in most cases, does not extend outward from the outer surface of the modified root portion 710.

[0074] In step 345, the external volumes of the diaphyseal and apical sections of the lower root portion of the sixth model of step 340 may be reduced in size (e.g., the cross-sectional diameter along the length of the diaphyseal and / or apical sections may be reduced) to provide space for the application of a porous exterior surface, thereby generating a seventh model of the tooth for use in designing a dental implant. Performing step 345 may be accomplished, for example, by shifting the outer edges of the diaphyseal and / or apical sections of the sixth root model inward by, for example, 0.1 to 1.0 mm, thereby reducing the volume of the remaining diaphyseal and apical sections of the root analog dental implant model by, for example, 3-5%. Optionally, performing step 345 may include adding one or more struts to the sixth model, for example, to improve the structural integrity of the implant.

[0075] The porous outer surface may be 0.1-2.0 mm deep, may be, for example, a lattice structure, and / or may include one or more holes or spaces therein into which bone may grow when a root analog implant manufactured using a model developed through execution of process 300 is placed into the alveolar socket. Exemplary specifications for the porous outer surface include a porosity in the range of 40-85%, a surface thickness in the range of 0.1-2 mm or 0.5-0.65 mm, and an average pore size in the range of 200-600 micrometers.

[0076] In some embodiments, the porous outer surface can be a series of overlapping and / or interconnected structures or strands and / or a matrix or mesh of material. The structure of the porous outer surface can be achieved by using additive manufacturing techniques such as 3D printing, which uses, for example, laser, selective laser sintering, and / or electron beam (E-beam), or other focused energy to fuse powdered biocompatible materials (e.g., titanium and / or ceramic) into a specific solid. In some examples, fabrication of a root analog dental implant involves overlaying the porous outer surface on a base. In some embodiments, the porous outer surface can be configured to be fabricated layer-by-layer simultaneously with the core or internal components of the root analog dental implant. In some cases, the porous surface can be added uniformly (e.g., the thickness of the porous coating and / or lattice network can be uniform throughout) or non-uniformly (e.g., the thickness of the porous surface can be non-uniform throughout).

[0077] In some cases, one or more characteristics of the porous outer surface (e.g., density, diameter of the lattice-containing threads, thickness, degree of interconnectivity, overlap pattern, pattern, width, length, etc.) may be configured according to, for example, strength and / or application requirements for the dental implant and / or clinician preferences. In some embodiments, one or more porous surface characteristics may be configured to match and / or be compatible with the bone characteristics of the alveolar socket and / or the characteristics of the extracted tooth. Exemplary bone and / or tooth characteristics include, but are not limited to, density, tissue type, and whether disease is present in the patient's mouth and / or body. In some embodiments, the porous outer surface, or portions thereof, may include one or more protrusions extending from its outer edge. The protrusions may be configured to engage the bone of the alveolar socket and improve retention within the socket. Exemplary shapes of the protrusions include spikes and knobs.

[0078] In some embodiments, the porous outer surface may include small or nano-sized surface features (e.g., texturing, dimples, or cross-hatching) that may be configured to provide, for example, a lattice pattern, struts, or other surface texture on the outer surface of the porous surface element that favors osseointegration. Sometimes these features may be present throughout the entire porous outer surface, and other times, micro- or nano-sized surface texture elements may be present only at or toward the outer surface of the root section of the root analog dental implant.

[0079] 9A and 9B provide one example of how step 345 may be performed to generate a first version of the seventh model 900. In particular, FIG. 9A provides a mesial or distal view of the first version of the seventh model 900, and FIG. 9B provides a buccal or lingual view of the first version of the seventh model 900. The first version of the seventh model 900 includes an abutment 860, an exposed portion 855, an exposed border 850, a coronal sulcus array 840, a portion of the modified root portion 710, a diaphyseal and apex section 920 having a reduced horizontal cross-sectional area relative to the modified root portion 710 that has been reduced via performance of step 345, and a tip 925.

[0080] 10A and 10B provide another example of how step 345 may be performed to generate a second version of the seventh model 1000. In particular, FIG. 10A provides a mesial or distal view of the second version of the seventh model 1000, and FIG. 10B provides a buccal or lingual view of the second version of the seventh model 1000. The second version of the seventh model 1000 includes an abutment 860, an exposed portion 855, an exposed boundary 850, a coronal sulcus array 840, a modified root portion 710, a diaphyseal and apex section 1020 having a reduced horizontal cross-sectional area relative to the modified root portion 710, which has been reduced through performance of step 345, and a tip 1025. The second version of the seventh model 1000 also includes a first strut 1030A and a third strut 1030C extending from the outer surface of the diaphyseal and apex section 1020. The first strut 1030A and the second strut 1030B may be configured to provide structural support for an implant manufactured using the second version of the seventh model 1000. FIG. 10B provides a bottom view of the second version of the seventh model 1000 with a strut design superimposed thereon, including six struts arranged in a star configuration. The strut design of FIG. 10B may be a base or default strut design superimposed on the modified root portion 710 to identify where (if any) the outer surface of the strut extends beyond the outer surface of the modified root portion 710 and / or diaphyseal and apex section 1020. If the outer surface of the strut extends beyond the outer surface of the modified root portion 710 (as is the case with the first strut 1030A and the second strut 1030B), the strut may be included in the seventh model. If the outer surface of the strut does not extend beyond the outer surface of the diaphysis and apex section 1020 (as is the case with the third strut 1030C, the fourth strut 1030D, the fifth strut 1030E, and the sixth strut 1030F), the strut may not extend from the outer surface of the diaphysis and apex section 1020 as shown in Figures 10A and 10B.This is because, for example, these sides of the diaphysis and apex section 1020 may be structurally sound enough to be positioned within the patient's alveolar socket and provide the strength needed to support the root analog dental implant and / or maintain implant integrity during the life of the root analog dental implant while withstanding, for example, the forces of biting and chewing.

[0081] Next, a porous outer surface (e.g., a lattice or a series of overlapping structures in which recesses or holes are arranged) may be applied to the diaphysis and apex section 1020 of the seventh model, thereby generating an eighth model of the tooth for use in designing a dental implant (step 350). The outer geometry of the porous outer surface may match the outer geometry of the lower root portion of the root model (e.g., modified root portion 710), such that, for example, the porous outer surface engages the inner wall of the corresponding portion of the alveolar socket. The porous outer surface may be configured, for example, to engage the inner wall of the alveolar socket and / or to provide a surface that allows osteointegration of the root analog dental implant with the alveolar socket.

[0082] 11A and 11B provide mesial / distal and buccal / lingual views, respectively, of an exemplary eighth model 1100, including an exemplary porous outer surface 1120 applied to the diaphyseal and apical portions of the seventh model 1000.

[0083] Optionally, in step 355, a final model of the implant may be designed and / or generated. Performance of step 355 may include, for example, adding a crown or other covering for the abutment. Figures 12A and 12B provide buccal / lingual and mesial / distal views, respectively, of an exemplary final model 1200 including an exemplary crown 1210 placed on an abutment 860, where the shape of the lower edge of the abutment 1210 matches the shape of the exposed boundary 850.

[0084] Optionally, in step 360, a design check of the seventh model and / or the final dental root analog dental implant model of step 360 may be performed to determine whether the dental root analog dental implant model is properly designed and complies with, for example, all dental implant, patient, and / or clinician requirements. Performing a design check may include, for example, comparing the final model of the root analog dental implant with original three-dimensional images and / or scans of the extracted tooth root, comparing the final model of the dental implant with design parameters for the dental implant, and / or comparing the final root analog dental implant model with images, three-dimensional scans, and / or impressions of the alveolar socket from which the root was extracted. In some embodiments, the design check may involve performing steps to determine whether the dental implant will function properly, for example, whether it has sufficient surface area for osteointegration and / or sufficient strength (e.g., for durability and functionality). For example, the design check of step 360 may include comparing parameters of the final model with, for example, predetermined root analog dental implant design specifications and / or requirements. For example, the design check of step 360 may include comparing the surface area of ​​the root portion of the final model and / or the strength of the dental implant at different points (which may, for example, be mathematically modeled) to certain regulatory standards, such as standards set by government agencies (e.g., the U.S. Food and Drug Administration (FDA) and / or the European Medicines Agency) and / or medical and / or dental review organizations or agencies (e.g., the American Dental Association (ADA) and / or the European Association for Dental Public Health (EADPH)).

[0085] In some embodiments, performing step 360 includes overlaying a rendering of the seventh model and / or the final implant model onto an image of the patient's jaw or mouth (e.g., an MRI, CT scan, intraoral scan, and / or X-ray) to see how an implant manufactured using the seventh and / or final model might fit into the alveolar socket and / or within the patient's mouth, e.g., relative to other teeth in the patient's mouth. FIG. 12C provides a mesial rendering of model 1200 placed within a CT scan of the alveolar socket from which tooth 400 was extracted. This rendering can be inspected to determine, for example, whether the coronal sulcus aligns with the ridge of the alveolar socket and / or whether the implant will fit properly within the patient's alveolar socket.

[0086] If the seventh and / or final model does not pass the design check (step 365), an error analysis of the seventh and / or final model may be performed, resulting in adjustments to the seventh and / or final model (step 370). After these adjustments, step 360 may be performed iteratively again. If the seventh and / or final model passes the design check (step 365), the seventh and / or final model may be formatted for manufacturing (step 375). In some embodiments, performing step 375 may include generating one or more instructions for manufacturing a root analog dental implant based on the seventh and / or final model. In some cases, performing step 375 includes converting the seventh and / or final model into CAM software for communication to a manufacturing device (e.g., a three-dimensional printer). In some embodiments, performing step 375 may include receiving or adapting instructions for generating the root analog dental implant based on the material (e.g., titanium or other biocompatible material) and / or additive manufacturing process used to manufacture the root analog dental implant. In step 380, the formatted seventh and / or final model and / or instructions for manufacturing a root analog dental implant based on the seventh and / or final model may be communicated to an implant fabrication tool, such as a 3D printer.

[0087] In some embodiments, the coronal features added in step 325 above may differ from those shown in Figures 8A-12C. For example, the coronal features may include a series of extensions and / or depressions in the surface of the coronal portion of the root analog dental implant model and / or root analog dental implant that may be positioned to replicate or approximate the shape of the modeled bone crest for the tooth. Additionally or alternatively, one or more of the implant models disclosed herein may include one or more features positioned in the coronal portion that do not approximate the shape of the modeled bone crest, such as protrusions or spikes.

[0088] 13A-17 provide several exemplary different coronal feature types and arrangements that may be added to a dental implant model, for example, via performance of step 325. For example, FIGS. 13A and 13B provide anterior and side views, respectively, of a dental implant model 1300 including an array of coronal grooves 840 and a plurality of four horizontally oriented coronal features 1310A, 1310B, 1310C, and 1310D arranged as shown. The coronal features 1310A, 1310B, 1310C, and / or 1310D may extend from and / or be recessed into the modified root portion 710. In another example, Figure 14A provides a mesial or distal side view of a dental implant model 1401 including an array of coronal grooves 840 and a vertically oriented coronal feature 1410A disposed below the array 840, and Figure 14B provides a mesial or distal side view of a dental implant model 1402 including an array of coronal grooves 840 and a first coronal feature 1410A, a second coronal feature 1410B, and a third coronal feature 1410C that are substantially vertically oriented and arranged in a fan-like configuration. Figure 15A provides a mesial or distal side view of a dental implant model 1501 including an array of coronal grooves 840 and a first horizontally oriented coronal feature 1520A that circumferentially surrounds the model 1501 and is disposed near the porous outer surface of the model 1501. Figure 15B provides a mesial or distal side view of a dental implant model 1502 including a first horizontally oriented coronal feature 1520A and a second horizontally oriented coronal feature 1520B positioned near the porous outer surface of the implant model. Figure 16 provides a mesial or distal side view of a dental implant model 1600 including an array of coronal grooves 840 and a tapered, horizontally oriented coronal feature 1620 positioned near the porous outer surface of the implant model. Figure 17 provides a mesial or distal side view of a dental implant model 1700 including an array of coronal grooves 840 and an extension 1710 in the form of a semi-conical spike positioned near the porous outer surface of the implant model 1700.

Claims

1. 1. A root analog dental implant configured to replace a tooth extracted from a patient's alveolar socket, the alveolar socket having a bony ridge corresponding to a point where an interface between a root of the patient's tooth and the alveolar socket terminates circumferentially on the root of the tooth prior to extraction, an exposed portion configured to abut a root boundary of a root portion of the root analog dental implant; the root portion configured to occupy a space in the alveolar socket at or below the bony ridge after extraction of the tooth, and the shape of the root boundary corresponds to the shape of the bony ridge; 1. A root analog dental implant comprising:

2. The crown of the root portion is a coronal groove circumferentially surrounding the coronal portion of the root portion of the root analog dental implant, the shape of the coronal groove corresponding to the shape of the root boundary; 10. The root analog dental implant of claim 1, further comprising:

3. a plurality of crown grooves, each of the plurality of crown grooves having a shape corresponding to the shape of the root boundary; 3. The root analog dental implant of claim 2, further comprising:

4. The root analog dental implant of claim 3 , wherein the distance between each of the plurality of coronal grooves is the same.

5. The root analog dental implant of claim 3 , wherein the distance between each of the plurality of coronal grooves varies along the length of the coronal portion.

6. 6. The root analog dental implant of claim 3, 4, or 5, wherein the number of coronal sulci included in the plurality of coronal sulci is responsive to at least one of a clinician's preference and a patient's characteristics.

7. 6. The root analog dental implant of claim 3, 4, or 5, wherein the number of coronal grooves included in the plurality of coronal grooves depends on at least one of the following: patient characteristics, aesthetic features of the root analog dental implant, clinician preferences, features that affect the appearance of a crown associated with the root analog dental implant, characteristics of the tooth, tooth position, and characteristics of the alveolar socket.

8. 8. The root analog dental implant of claim 7, wherein the patient's characteristic is low bone density surrounding the alveolar socket, and the number of coronal sulci included in the plurality of coronal sulci is increased from a baseline number of coronal sulci in response to the patient's low bone density.

9. porous surface 6. The root analog dental implant of claim 1, further comprising:

10. 10. The root analog dental implant of claim 9, wherein the porous surface is disposed in a diaphyseal portion and an apical portion of the root portion.

11. 6. The root analog dental implant according to claim 1, wherein the external shape of the root analog dental implant corresponds to the shape of the alveolar socket.

12. The root portion is support structure 6. The root analog dental implant of claim 1, further comprising:

13. The root analog dental implant of claim 12 , wherein the support structure is a post.

14. The root analog dental implant of claim 1 , wherein the root analog dental implant includes an abutment positioned adjacent to the exposed portion.

15. 6. The root analog dental implant of claim 1, wherein the shape of the exposed portion is responsive to at least one of a clinician's preference and a patient's characteristics.

16. 6. A root analog dental implant as described in any one of claims 1 to 5, wherein the root portion further comprises one or more of an extension, a tapered horizontally oriented coronal feature, a horizontally oriented coronal feature, a vertically oriented coronal feature, an array of tapered horizontally oriented coronal features, an array of horizontally oriented coronal features, and an array of vertically oriented coronal features.

17. 6. The root analog dental implant according to claim 1, wherein the root analog dental implant is one piece.

18. 6. The root analog dental implant of claim 1, wherein the root analog dental implant is manufactured using an additive manufacturing process.

19. 6. The root analog dental implant of claim 1, wherein the shape of at least one of the exposed portion and the root portion is responsive to at least one of a clinician's preference and a patient's characteristics.

20. 6. The root analog dental implant of claim 1, wherein the root boundary closely conforms to the shape of the bone ridge.

21. 1. A method for designing a root analog dental implant, comprising: receiving size, shape, and crest characteristics of the extracted tooth; determining a shape of a root boundary of a root portion of the root analog dental implant using features of the bone crest; preparing a model of the extracted tooth using the received size, shape, and bony crest characteristics of the extracted tooth, the model including the root portion and an exposed portion configured to abut the root border of the root portion; A method comprising:

22. generating a set of instructions for fabricating the root analog dental implant based on the model; providing said set of instructions to a root analog dental implant manufacturing machine; 22. The method of claim 21 further comprising:

23. adding a coronal groove to the root portion of the model, the shape of the coronal groove corresponding to the root boundary; 23. The method of claim 22, further comprising:

24. receiving at least one of patient characteristics, aesthetic features of the root analog dental implant, features that affect the appearance of a crown associated with the root analog dental implant, clinician preferences, characteristics of the extracted tooth, and characteristics of the alveolar socket from which the extracted tooth is extracted, wherein the model is further prepared using the at least one patient characteristics, clinician preferences, characteristics of the tooth, and characteristics of the alveolar socket.

23. The method of claim 21 or 22, further comprising:

25. 25. The method of claim 24, wherein the characteristics of the alveolar socket include at least one of bone thickness and bone density.

26. 25. The method of claim 24, wherein the feature that affects the appearance of the crown cooperating with the root analog dental implant corresponds to the position of a root portion of the root analog dental implant relative to the gingiva surrounding the alveolar socket from which the tooth was extracted.

27. 1. A root analog dental implant configured to replace a tooth extracted from a patient's alveolar socket, the alveolar socket having a bony ridge corresponding to a point where an interface between a root of the patient's tooth and the alveolar socket terminates circumferentially on the root of the tooth prior to extraction, a coronal groove circumferentially surrounding a coronal portion of the root portion of the root analog dental implant, the curvature of the coronal groove corresponding to the curvature of the bone ridge; 1. A root analog dental implant comprising:

28. Multiple coronary sulci 28. The root analog dental implant of claim 27, further comprising:

29. 30. The root analog dental implant of claim 28, wherein the distance between each of said plurality of coronal grooves is the same.

30. 30. The root analog dental implant of claim 28, wherein the distance between each of said plurality of coronal grooves varies along the length of said coronal portion.

31. 31. The root analog dental implant of claim 28, 29, or 30, wherein the number of coronal sulci included in the plurality of coronal sulci is responsive to at least one of clinician preference and patient characteristics.

32. 31. The root analog dental implant of claim 28, 29, or 30, wherein the number of coronal sulci included in the plurality of coronal sulci depends on at least one of patient characteristics, aesthetic features of the root analog dental implant, clinician preferences, characteristics of the teeth, tooth position, and characteristics of the alveolar socket.

33. 33. The root analog dental implant of claim 32, wherein the patient's characteristic is low bone density surrounding the alveolar socket, and the number of coronal sulci included in the plurality of coronal sulci is increased from a baseline number of coronal sulci in response to the patient's low bone density.

34. porous surface 31. The root analog dental implant of any of claims 27 to 30, further comprising:

35. 35. The root analog dental implant of claim 34, wherein the porous surface is disposed in a diaphyseal portion and an apical portion of the root analog dental implant.

36. 31. A root analog dental implant according to any of claims 27 to 30, wherein the external shape of the root analog dental implant corresponds to the shape of the alveolar socket.

37. support structure 31. The root analog dental implant of any of claims 27 to 30, further comprising:

38. 38. The root analog dental implant of claim 37, wherein the support structure is a post.

39. 31. The root analog dental implant of any of claims 27 to 30, wherein the root analog dental implant comprises an exposed portion and an abutment.

40. The root analog dental implant comprises: an exposed portion configured to abut a root boundary of a root portion of the root analog dental implant; a root portion configured to occupy a space in the alveolar socket at or below the bony ridge after extraction of the tooth, the shape of the root boundary corresponding to the shape of the bony ridge; 31. The root analog dental implant of any of claims 27 to 30, further comprising:

41. 40. The root analog dental implant of claim 39, wherein the shape of the exposed portion is responsive to at least one of a clinician's preference and a patient's characteristics.

42. 40. The root analog dental implant of claim 39, wherein the shape of the coronal groove further corresponds to the shape of the root boundary.

43. 31. A root analog dental implant as described in any of claims 27 to 30, further comprising one or more of an extension, a tapered horizontally oriented coronal feature, a horizontally oriented coronal feature, a vertically oriented coronal feature, an array of tapered horizontally oriented coronal features, an array of horizontally oriented coronal features, and an array of vertically oriented coronal features.

44. 31. The root analog dental implant of any of claims 27 to 30, wherein the root analog dental implant is one piece.

45. 31. The root analog dental implant of any of claims 27 to 30, wherein the root analog dental implant is manufactured using an additive manufacturing process.

46. 31. The root analog dental implant of any of claims 27 to 30, wherein the shape of the root portion of the root analog dental implant is responsive to at least one of clinician preference and patient characteristics.

47. 1. A method for designing a root analog dental implant, comprising: receiving size, shape, and crest characteristics of the extracted tooth; preparing a model of the extracted tooth using the received size, shape, and bony crest characteristics of the extracted tooth, the model including a modeled bony ridge that approximates the bony crest characteristics; adding a coronal sulcus to the model, the coronal sulcus having features corresponding to the modeled bony ridge; A method comprising:

48. providing said model with said added coronal groove to a root analog dental implant manufacturing machine; 48. The method of claim 47, further comprising:

49. receiving at least one of patient characteristics, aesthetic features of the root analog dental implant, clinician preferences, characteristics of the extracted tooth, and characteristics of the alveolar socket from which the extracted tooth is extracted, wherein the model is further prepared using the at least one patient characteristics, clinician preferences, characteristics of the tooth, and characteristics of the alveolar socket.

49. The method of claim 47 or 48, further comprising:

50. 50. The method of claim 49, wherein the characteristics of the alveolar socket include at least one of bone thickness and bone density.

51. 50. The method of claim 49, wherein the aesthetic features of the root analog dental implant correspond to the location of a root portion of the root analog dental implant relative to the gingiva surrounding the alveolar socket from which the tooth was extracted.

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