Processes and systems for personalized orthodontic aligner sets based on treatment plans
Patent Information
- Application Number
- JP2026512301
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-08-22
- Filing Date
- 2024-08-22
- Publication Date
- 2026-09-08
Smart Images
Figure 2026530445000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a method for manufacturing an orthodontic aligner set comprising at least two aligners made of different aligner shell materials, the method comprising at least the following manufacturing steps: a) providing at least two different physical dental models, wherein the dental model comprises a base plate and a dentition arrangement thereon, the dentition arrangement defines at least a part of the patient's current or future dentition arrangement, each model comprises an individual identifier, and the identifier comprises information encoding at least a specific patient and an aligner shell material; b) placing at least one of the physical dental models provided in step a) into a deep drawing chamber; c) reading the individual identifier on the physical dental model and presenting at least the encoded information related to the aligner shell material, wherein the reading is performed after step a) and before step d); d) selecting a specific aligner shell material represented by the encoded information in step c); e) placing the selected aligner shell material onto the physical dental model and heating the aligner shell material, wherein the heating is performed before, during or after the placement of the selected aligner shell material, and deep drawing the aligner shell material onto the physical dental model to manufacture a single orthodontic aligner; f) removing the dental model and the orthodontic aligner from the deep drawing chamber; g) repeating steps b) to f) until each physical dental model of the set has been processed. Furthermore, the present invention also relates to a system for manufacturing an aligner set comprising one or more orthodontic aligners. Background Art
[0002] Orthodontics is a dental treatment that manipulates the position of teeth to correct malocclusion in the upper and lower dental arches. Traditionally, the treatment of such malocclusion has involved the use of orthodontic appliances that apply orthodontic force to the teeth. During the course of treatment, these mechanical forces move the teeth into orthodontally correct positions. One known method of applying such orthodontic force is the use of "braces," often called orthodontic brackets. Treatment with standard brackets involves attaching brackets to each tooth being treated. These brackets are then connected to an archwire using ligatures. The archwire is elastic and applies the necessary mechanical force to the teeth via the brackets. Alternatively, instead of wearing braces that remain bonded to the patient's teeth throughout the treatment period, dentists can use orthodontic appliances called dental aligners, or simply aligners. Aligners are removable dental appliances, usually provided in a series of different structures, each capable of progressively moving the patient's teeth from an initial position through an intermediate position to an orthodontally correct and aesthetically pleasing final position. Aligners are usually transparent and therefore "invisible," and are easy to handle. However, to ensure an efficient and reliable manufacturing process, it is necessary to consider that multiple different aligners, including those with different dentition configurations, must be processed for a single patient. Unfortunately, the situation becomes even more complex when, in addition to dentition configuration, other aligner characteristics must also be adapted during the manufacturing process. Implementing such fluctuating product requirements into existing aligner manufacturing processes is extremely difficult and therefore prone to errors.
[0003] Different processes for manufacturing dental aligners are also described in the patent documents.
[0004] For example, EP2467088A1 describes a method for manufacturing orthodontic aligner trays, which includes: obtaining an original digital model of the patient's teeth; segmenting the teeth represented by the digital model; repositioning at least one tooth to the correct position to create a final dentition model representing the final dentition position; superimposing the final dentition model onto the original digital model to create a digital overlay model including a start point defined by the original digital model and an end point defined by the final dentition model; manufacturing at least one aligner tray based on the overlay model and defining tooth compartments within each aligner; and inserting at least one force device positioned within the tooth compartments into at least one aligner tray to apply selected forces to selected teeth.
[0005] Another patent document, US2006 / 093982A1, discloses a method for manufacturing a physical dental aligner, which includes: creating a digital dental aligner model suitable for CNC-based manufacturing based on a digital dental arch model; segmenting the digital dental aligner model into multiple manufacturable digital parts; manufacturing aligner parts according to the digital aligner parts using computer numerical control (CNC) based manufacturing; and assembling the aligner parts to form a physical dental aligner.
[0006] WO2021 / 098759A1 describes a method for manufacturing dental aligners. This method includes scanning a patient's teeth to create a 3D printable file, adjusting the 3D printable file according to a treatment plan, printing a dental aligner mold based on the adjusted 3D printable file, and manufacturing dental aligners from the dental aligner mold.
[0007] Such solutions, known from prior art, may have room for further improvement. This is particularly related to efficiency in the manufacturing process of a series of different aligners and the ability to safely handle different aligner materials. [Overview of the project]
[0008] Therefore, the object of the present invention is to overcome, at least partially, the drawbacks known from the prior art. In particular, the object of the present invention is to provide an aligner manufacturing process that enables the safe and efficient use of different aligner materials. Thus, as a secondary effect, the physical properties of the aligner set are improved by adapting or adjusting the aligner material to the specific needs of the patient.
[0009] This problem is solved by the features of the independent claims relating to the processes and systems according to the present invention. Preferred embodiments of the present invention are shown in the dependent claims, specification or drawings, and further features described or outlined in the dependent claims, specification or drawings may constitute the subject matter of the present invention individually or in any combination, unless the context explicitly indicates otherwise.
[0010] According to the present invention, the problem is solved by a method for manufacturing an orthodontic aligner set comprising at least two aligners made of different aligner shell materials, the method comprising at least the following manufacturing steps: a) To provide at least two different physical dental models, wherein each dental model includes a base plate and a dentition configuration thereon, the dentition configuration defining at least a portion of the patient's current or future dentition configuration, and each model includes an individual identifier, the identifier including information encoding at least a specific patient and aligner shell material; b) Placing at least one of the physical dental models provided in step a) into a deep drawing chamber; c) Read individual identifiers on the physical dental model and provide coded information relating at least to the aligner shell material, wherein the reading is performed after step a) and before step d); d) Selecting a specific aligner shell material represented by the coded information in step c); e) Placing the selected aligner shell material onto a physical dental model, heating the aligner shell material (heating is performed before, during, or after placement of the selected aligner shell material), and deep drawing the aligner shell material onto the physical dental model to manufacture a single orthodontic aligner; f) Removing the dental model and orthodontic aligner from the deep-drawn chamber; g) Repeat steps b) through f) until each physical dental model in the set has been processed.
[0011] Surprisingly, the above process was found to be very suitable for the safe and efficient handling of different aligner materials. Typically, only one aligner material is used for processing a single patient's aligners, and the aligner material, in the form of a polymer sheet or polymer laminate, is manually placed in a deep drawing machine and deep-drawn onto the patient's specific dental model. Based on the fact that there is no variation in the sheet material during the patient-specific manufacturing process, such a process is safe and reliable. However, when different sheet materials are required in the overall treatment plan depending on the treatment stage, such handling is laborious and prone to errors because the appropriate aligner material must be selected according to the patient, the dental model, and in certain cases, according to the application time of the same dental model. Because the appearance of different aligner sheet materials is similar, it is very difficult to detect errors, and therefore, process means must be implemented to eliminate failures in the selection and application of aligner sheet materials to the treatment stage-specific dental model. Only such an adapted process enables the efficient production of a complete aligner set without the need to manufacture only a single aligner for the same treatment stage. Surprisingly, it was also found that adapting the aligner shell material according to the dental treatment planning stage allows for more efficient and rapid tooth movement. This can be used to provide a treatment plan using fewer but more efficient aligner shells. [Brief explanation of the drawing]
[0012] [Figure 1] Schematic diagram of possible process steps according to the present invention [Figure 2] Schematic diagram of a possible system according to the present invention [Figure 3] Schematic diagram of a possible system according to the present invention [Figure 4] Schematic diagram of the system according to the present invention [Figure 5] Schematic diagram of the system according to the present invention [Figure 6] Schematic diagram of the system according to the present invention [Modes for carrying out the invention]
[0013] The present invention relates to a method for manufacturing a set of orthodontic aligners comprising at least two aligners made of different aligner shell materials. Processing dental aligners typically involves thermoforming a plastic sheet onto a model of the patient's dentition. The model can be constructed directly from a virtual model, such as a stereolithography (SLA) machine or other rapid prototyping device, or it can be cut from bulk material by CNC machining. A series of positive models are constructed within the treatment plan, each model corresponding to a specific position in the patient's future dentition and a three-dimensional reproduction of the patient's teeth at a specific target position during treatment. Multiple models are usually required to achieve sufficient orthodontic treatment of the patient's teeth. The treatment plan can be based on different phases, each phase involving different tasks related to tooth movement. Such segmentation of the treatment plan is useful and can potentially reduce the overall treatment time. Different aligner materials can be used depending on the treatment phase to adapt the aligner material to the tasks in the treatment phase. Therefore, different aligners made of different materials must be used. Preferably, an aligner set including one or more different aligners, preferably aligners made of different aligner shell materials, may include more than 2 but less than 10, preferably more than 5 but less than 15, and more preferably more than 10 but less than 20 individual aligners.
[0014] Process step a) includes providing at least two different physical dental models, each dental model including a base plate and a dentition configuration thereon, where the dentition configuration defines at least a portion of the patient's current or future dentition configuration, and each model includes an individual identifier, where the identifier includes information encoding at least a specific patient and aligner shell material. The dental model is a physical model, and such a model can be fabricated by any means in accordance with the level of technology described above. The dental model represents the patient's desired future dentition configuration, and the model can represent the maxillary, mandibular, or bimaxillary dentition configuration. Furthermore, this model does not need to represent the complete dental arch; it is also possible that only some teeth or specific portions of the dental arch are represented. The dental model can be based on a digital model created by treatment planning software. Within the planning software, teeth are digitally moved in specific stages or movement characteristics. According to the digital plan, specific steps / models and movements can be manually or automatically tagged with specific foils for this model for the manufacture of specific aligners of specific materials. A physical model includes at least a base plate or base, on which a specific dentition configuration is placed. Furthermore, in addition to teeth, a portion of the gingival line or other dental or oral features may also be represented by the model or base plate. Identifiers can exist in the form of visually, tactilely, or electronically accessible identifiers. Thus, identifiers can present stored information in different ways. Reading can be based on visual, tactile, or electronic means. Identifiers can be used to store multiple different pieces of information, at least one of which may be available for patient identification. At least one other piece of information may relate to a specific aligner material that must be used for this model. This information may also include information that different materials must be used for the model, and further may include manufacturing instructions for available sheet materials.Additional information that can be coded with identifiers and may affect the material properties of the sheet during the manufacturing process includes, for example, heating time, heating temperature, cooling time, machine type, sheet temperature before thermoforming, or foil surface temperature as assessed by a machine temperature detector.
[0015] Process step b) includes placing at least one of the physical dental models provided in step a) into a deep drawing chamber. The aligner shell is fabricated by deep drawing aligner shell material onto the physical model. The model is placed in the deep drawing chamber to form the shell material into the model. The chamber can provide the process conditions required for deep drawing. This typically includes the application of vacuum or reduced pressure and / or heating of the chamber environment. Furthermore, the chamber also includes means for performing and controlling the deep drawing process with respect to process time and heating or reduced pressure ramps.
[0016] Process step c) includes reading individual identifiers on a physical dental model and presenting coded information relating at least to the aligner shell material, the reading being performed after step a) and before step d). The reading of coded information relating to individual identifiers may be performed before the physical model is placed in the deep drawing chamber. It is also possible that the information be evaluated while the model is being placed in the chamber or after the model is placed in the chamber. The reading can be performed as a function of the identifier used, i.e., the information can be accessed visually, electronically or tactilely. Based on the different method of accessing the information, the reading can be performed electronically, for example, by reading RFID chip information with an RFID reader. The reading can also be performed visually by a camera or scanner. The presentation of information accessed from the identifier may include outputting the information onto a screen. Alternatively, the presentation may include inputting the information into a computer system, where the information can be further processed.
[0017] Process step d) comprises selecting the specific aligner shell material represented by the information encoded in process step c). The specified aligner shell material is selected from a plurality of different aligner shell materials in this step. The specified aligner shell material for this model can be manually retrieved from a storage location. In this case, the material suitable for this model is represented by the preceding process step, so an operator can select the appropriate material. Alternatively, the material can also be automatically retrieved from a storage location dedicated to the material, for example by a robot. It is also possible to apply a combination of manual and automatic sub-steps in this process step.
[0018] Process step e) comprises placing the selected aligner shell material onto the physical dental model, heating the aligner shell material, wherein the heating is performed before, during or after the placement of the selected aligner shell material, and deep-drawing the aligner shell material onto the physical dental model to produce a single orthodontic aligner. Within this step, the aligner shell material is physically prepared for the deep-drawing process. This preparation includes warming or heating the aligner shell foil material. The heating is preferably performed in a chamber, but nevertheless, it is also possible to place the preheated foil material into the chamber and immediately deep-draw the already heated sheet. Preferably, the selected aligner shell material is heated, placed onto the physical dental model, and thermoformed on the model.
[0019] Process step f) comprises removing the dental model and the orthodontic aligner from the deep-drawing chamber. After the aligner shell material has been formed to the contour of the model, the (substantially) completed aligner is removed from the model and the chamber. Before the final aligner ready for application is obtained, the aligner can be subjected to post-processing, for example in the form of edge trimming, cleaning, polishing or similar processes.
[0020] Process step g) comprises repeating process steps b) to f) until each physical dental model of the set has been processed. In order to adapt the aligner shell material to a specific stage in the orthodontic treatment process, it has been found that multiple aligners made of different shell materials provide better orthodontic outcomes compared to single-material approaches where only one shell material is used throughout the treatment. The overall aligner manufacturing process can be repeated multiple times, and different shell materials can be used for each model corresponding to a desired treatment stage. Different shell materials result in different physical properties of the aligner. The physical properties can be adjusted to better suit the desired needs at a specific process stage. By repeating the process, the aligner shell material can be freely changed in accordance with stored information, and the complete set for a single patient can be processed sequentially or in parallel. This enables lean and efficient processing. Preferably, the process may be performed 5 or more times, preferably 10 or more times, to process a complete set for full dental treatment at one time.
[0021] In a preferred embodiment of the process, the individual identifier may be arranged under the base plate of the physical dental model. This specific arrangement of the identifier enables rapid and easy processing during the manufacturing process of the dental model, particularly during the process of accessing the identifier from the model around the deep drawing machine. The upper part of the model needs to be clean and in direct contact with the shell material. Therefore, when the identifier is arranged below rather than on the model, the reading operation can be expedited, and the dimensions of the deep drawing chamber can be kept smaller. The latter is particularly true because the means required for reading can be integrated into the bottom of the deep drawing machine, allowing the airtight deep drawing chamber to be made as small as possible. Such an arrangement also includes the advantage that after the deep drawing process, the identifier can be used for further scanning for post-processing processes such as automatic cutting. In this case, the identifier may also include cutting lines for laser or CNC machines. Since no foil is present over the identifier, the identifier remains visible / readable for post-processing steps.
[0022] In a preferred embodiment of the process, individual identifiers are placed on molars represented by a physical dental model. To facilitate and ensure the placement of identifiers, it has been found useful to place them on the upper molars of the model. The molars can be the maxillary first molar, maxillary second molar, maxillary third molar, mandibular first molar, mandibular second molar, or mandibular third molar. In this position, the identifier is not visible after aligner formation. The identifier can be a flat identifier, which is not transferred to the aligner shell material during deep drawing. Alternatively, the identifier can be mounted such that an impression of the identifier is also transferred to the aligner shell material during aligner formation. In this case, a marking is generated on the aligner shell, providing further information to the user of the aligner shell. In this embodiment, the identifier is used for two different purposes: on the one hand, to provide information for processing the aligner, and further, to provide information for the user. In this case, the identifier can also code the order of aligner application and the number of this particular aligner within the overall application order. Furthermore, when integrating individual identifiers on the upper part of the dental model over the molars, the identifiers may be positioned on the cusp side of the molar surface. This positioning is preferred because positioning the identifiers on the cusps results in less variation in the overall force for tooth movement. Any change in the aligner shell shape, such as a smaller thickness resulting from the integration of identifiers, can lead to different force profiles in the shell material during application. Therefore, not all locations on the dental model will result in similar force variations during aligner shell application. It has been found that positioning over the molars, particularly over the molar cusps, results in the least disturbance in the achievable force profile.
[0023] In a preferred embodiment of the process, the individual identifier further codes one or more deep drawing process parameters selected from the group consisting of heating temperature, heating time, applied pressure, process time under vacuum, post-processing, or a combination thereof. Depending on the aligner material used, it may also be useful to automatically adapt the individual deep drawing process according to the material used. In this case, all or some specific deep drawing parameters can also be stored in the individual identifier and retrieved before the start of the deep drawing process. Such a streamlined procedure can reduce the risk of individual errors during processing. Rather than storing only a single pressure and / or temperature value, it may be useful to include a more complex set of processing parameters, for example, with respect to time-dependent temperature and / or pressure profiles. Furthermore, additional post-processing steps, such as cleaning or cutting the aligner, can also be coded.
[0024] In a preferred embodiment of this method, in process step e), the selected aligner shell material is selected manually or automatically and placed on a physical dental model. It has been found useful that shell material in the form of polymer foil is selected and placed on the model either purely manually or purely automatically. Such a strict distinction between manual and automatic avoids confusion and results in a simple and lean process.
[0025] In a preferred embodiment of this method, the selected aligner shell material is automatically placed on the physical dental model in process step e), and in process step d), the selection of the aligner shell material includes transferring a specific aligner shell material from a material-specific storage location to a deep-drawing chamber and onto the physical dental model by a robotic arm, according to the presented coded aligner shell material information. The automated selection and automated process of aligner material into the deep-drawing chamber has been found to be very useful, especially when multiple deep-drawing chambers are operating simultaneously. Consistent processing ensures that the wrong material is not placed on the wrong model. In a more preferred embodiment, the robotic arm may also be provided with means to evaluate and cross-check identifiers in the vicinity of the model to ensure that the correct aligner wheel is transferred to the correct model.
[0026] In a preferred embodiment of this method, process step f) includes attaching individual tags to the orthodontic aligners after deep drawing and before removing the orthodontic aligners from the deep drawing chamber. It has been found useful to attach additional identifiers to the aligners themselves for further processing of the manufactured aligners. This identifier or tag can be applied to the aligners and can further indicate the patient or the order in which the aligners are applied. The tags may be in the form of printed codes, such as barcodes or QR codes®. Furthermore, the tags may be identifiers in the form of RFID codes and may be loosely attached to the aligners.
[0027] In a preferred embodiment of this method, the deep drawing chamber includes at least two independently controllable deep drawing stations, and process steps b) through f) are performed simultaneously for different physical dental models and for the same or different aligner shell materials arranged in process step e). Based on the fact that multiple different sheet materials can be safely processed in the process of the present invention, it has been found advantageous to have multiple deep drawing stations in the deep drawing chamber. The deep drawing stations can provide the same functionality as the deep drawing chamber but can offer the possibility of being independently controlled with respect to specific process parameters, such as temperature or pressure. This configuration allows for the simultaneous and independent processing of very different aligner materials in the same location.
[0028] In a preferred embodiment of this method, simultaneous processing of different dental models is performed automatically, and includes, at a minimum, the automatic selection and transfer of specific aligner shell materials from a material-dedicated storage location to a deep drawing location and onto different physical dental models by a robotic arm, according to the presented coded aligner shell material information. By automatically performing the necessary material selection and placement steps, the process can be carried out in the most efficient and safe manner. In particular, a robotic arm connected to a computer is suitable for performing tasks in a reproducible and reliable manner.
[0029] In a preferred embodiment, the physical dental model is a physical dental model obtained by a 3D printing process, the 3D printing process producing the physical dental model and one or more support structures that support the mechanical stability of the 3D printed physical dental model, and individual identifiers are attached to or incorporated into the support structures. Surprisingly, it has been found that 3D printed models in particular can be used in the process of the present invention. A dental model produced by 3D printing requires the presence of one or more 3D printed support structures, which mechanically stabilize the model and fix single model parts at desired relative intervals. Typically, these structures are removed after 3D processing and before aligner generation by deep drawing. Nevertheless, it has been found useful to mechanically stabilize the model during aligner formation using support structures that maintain their structure during the deep drawing process, do not interfere with the deep drawing process, and do not become part of the final aligner. This may improve the quality of the aligner shell because the 3D printed model is more stable. Furthermore, the support structures can be used to identify the model. Based on the fact that support structures are independent of the final aligner, they can be freely used to encode necessary information, such as shell material or patient information. Information can be encoded by attaching labels to one or more support structures. Alternatively, individual identifiers can be included in the support structures through the printing process itself. The latter embodiment eliminates the need for further material attachment. For example, identifiers can be integrated into the support structures by using different printing materials and generating barcodes on the support structures. It is also possible to print sequences of numbers or letters onto the support structures after they have been generated. Furthermore, it is possible to use an array of support structures to construct identifiers, where the 3D spacing between different support structures increases the amount of information that can be stored, or the support structures themselves can encode specific information. Here, it is also possible to position specific support structures to encode information. Such a support structure design facilitates overall handling and leaves no trace on the model itself.Preferably, the support structure can be positioned beneath the surface defining the dental model, allowing for easy evaluation of the support structure's information from below. Such embodiments result in greater handling space above the model and, based on higher precision in the placement of aligner shell material, better aligners. In preferred embodiments, the 3D printed dental model is a hollow 3D printed model, and apart from possible support structures within the model, the model includes a thin layer of printed tooth surface and does not contain any further printed material beneath the surface. The support structure can be positioned in the space beneath the tooth surface, or, in addition or alternatively, the support structure can be a support connection between or behind the last molars of the model. In the first option, the support structure is visible from below, making it possible to read identifiers from below the model. This embodiment allows for easy access to information without restricting headspace during deep drawing. Thus, the use of a 3D printed hollow dental model that includes support structures within the model facilitates the reading of identification marks contained within the support structures. The use of support structures connecting the last molars or the lower parts of the molars of the model results in efficient stabilization of the model and the possibility of reading identifiers placed on the support structures from "rear".
[0030] In a preferred embodiment of this method, at least five different physical dental models are processed, and for each physical dental model, a different aligner shell material is processed in process steps d) through f). The process of the present invention is particularly suited to processing different aligner shell materials, and different aligners are used at different stages of dental treatment. Different physical parameters of the aligners are achieved based on the different foils used to form the aligners at different stages, and the physical properties of the aligners can be selected to best suit the needs of a particular stage. For example, a treatment stage that rotates a single tooth may be best addressed by a different aligner material than the aligner used in a stage that adjusts the height of the tooth. For faster and more reliable treatment, it has been found that processing at least five different models is appropriate. It is also possible to process at least seven, and more preferably at least ten, different models.
[0031] Furthermore, a system for manufacturing an aligner set containing one or more types of orthodontic aligners is within the scope of the present invention, and the system includes at least the following: i) A physical dental model assembly unit, wherein the model assembly unit is configured to sequentially assemble one or more dental models, each including at least a base plate and a dentition configuration thereon; ii) An identification unit, wherein the identification unit is configured to apply at least one identifier to a physical dental model, the identifier comprising information that codes at least a specific patient and aligner shell material; iii) A deep drawing chamber configured to evaluate identifiers on a physical dental model, present coded aligner shell material obtained from the identifiers, and deep draw the aligner shell material onto the physical dental model at a deep drawing station to obtain an orthodontic aligner; iv) A disassembly unit configured to disassemble an orthodontic aligner from a physical dental model. Remarkably, the system described above was found to be capable of reliably processing large quantities of aligners in a short period of time. For the system, the ability to safely handle different aligner shell materials is essential. This handling is ensured, in particular, by features ii) and iii), where each dental model provides correct identification, at least with respect to the material being used. Further advantages of the system are explicitly referred to in the advantages of the process of the present invention.
[0032] The present invention relates to a system for manufacturing an aligner set comprising one or more types of orthodontic aligners. The system is configured to manufacture particularly different aligners, and the differences between the different aligners are based not only on different tooth configurations but also on different aligner shell materials. Safe and reliable processing of different shell materials is at the heart of the described system. An aligner set may include up to 5, preferably up to 10, and preferably up to 20 different aligners. Preferably, at least 5 different aligner shell materials are used in processing the aligners.
[0033] The system includes (i) a physical dental model assembly unit, which is configured to sequentially assemble one or more dental models, each including at least a base plate and a dentition configuration thereon. The assembly unit may be a standard assembly unit known to those skilled in the art. Different teeth can be processed and fixed on the base plate. Furthermore, the assembly unit can process different models by a 3D additive manufacturing process, and tooth structures can be added by a 3D printing process. Furthermore, it is also possible to generate dental structures from blocks by a milling procedure. The base plate is a more or less flat 2D structure on which the dental structure is placed. The base plate may further include or mimic features from a patient's oral cavity.
[0034] The system includes (ii) an identification unit, which is configured to apply at least one identifier to a physical dental model, the identifier containing information that codes at least a specific patient and aligner shell material. The identification unit may be, for example, a printer, which applies ink to the surface of the model. The identification unit may also apply laser-based visual identification, where the laser visually alters the surface of the model. Alternatively, the identification unit may apply an electronically readable chip, such as an RFID chip, to the surface of the model. The visual, tactile, or electrical identifier may be, for example, in the form of a barcode, QR code (registered trademark), or RFID electrical code, and may contain information about at least a specific patient and the shell material, i.e., the polymer foil to be used when processing the aligners for this model. The identifier may also contain a code indicating that this model must be processed multiple times.
[0035] The system includes iii) a deep drawing chamber, which evaluates identifiers on a physical dental model, presents coded aligner shell material obtained from the identifiers, and is configured to deep draw the aligner shell material onto the physical dental model at a deep drawing station to obtain orthodontic aligners. The deep drawing chamber may include a camera, a barcode reader, an RFID reader, or any other means capable of extracting coded information and providing the information to an operator or computer system. Furthermore, the deep drawing chamber may include additional standard functions of the deep drawing unit, such as a heater, a vacuum unit, and a control unit, which are configured to control the execution of temperature and pressure programs.
[0036] The system includes iv) a separation unit configured to separate the orthodontic aligners from the physical dental model. After deep-pressing the polymer sheet onto the dental model, it is necessary to separate the model from the aligners. Such a unit may be equipped to peel or lift the aligners from the model. Furthermore, this unit may also be suitable for performing certain post-processing tasks, such as trimming the edges, final cutting of excess aligner material, or adding further stamping or another identifier to the top or inside of the final aligner.
[0037] In a preferred embodiment of this system, the identification unit is configured to apply at least one identifier below the baseplate. Placing the identifier below the baseplate allows for faster processing of the model and is also advantageous for reading the identifier. In particular, the design of the deep-drawn chamber can be made much more compact compared to when the identifier is placed on top of the model. The identifier can be applied to the side of the baseplate where there are no teeth or oral structures. This portion of the baseplate is not affected by the deep drawing and does not come into contact with the aligner shell material. Reading such an identifier is much quicker and easier compared to an identifier applied to the top of the model.
[0038] In a preferred embodiment of this system, the deep drawing chamber includes a camera unit configured to evaluate identifiers from below the base plate of a physical dental model and to present information about at least the aligner shell material. Evaluating identifiers from below through the bottom of the deep drawing chamber allows the necessary means to be integrated into the bottom of the machine. This ensures that there are no additional components inside the deep drawing chamber. This may facilitate handling of the aligner shell material as more space is available for manipulating the sheet within the unit.
[0039] In a preferred embodiment of this system, the system includes a computer unit and an automated aligner shell material supply unit, the computer unit being configured to receive information about aligner shell materials from a camera unit, and the automated aligner shell material supply unit being configured to receive information about aligner shell materials from the computer unit, select coded aligner shell materials from storage, and place the aligner shell materials in a deep drawing station on a physical dental model. The combination with the automated shell material supply unit allows for the processing of a wide variety of materials and enables the assembly of reliable and failure-free aligner sets. The storage area may include a single sheet material in a separate container, and the supply unit can retrieve the sheet material from the storage area and transport the sheet to or directly place it in the deep drawing chamber. The supply unit can be operated via a suction device or by electrostatic force. Furthermore, the supply unit may include additional means for detecting the correct placement of the aligner shell material on the model. In addition, the system may further include a heating unit, which is configured to heat the shell material before placing it on the dental model.
[0040] In a preferred embodiment of this system, the system includes a tagging unit configured to apply individual tags to orthodontic aligners after deep drawing. It has been found useful to include a tagging unit in the system to specify a particular application order for the final processed aligner shells, or to personalize the aligner shells for a particular patient. The tagging unit can print or laser engrave the necessary information onto the aligner shell itself.
[0041] In a preferred embodiment of this system, the deep drawing chamber includes at least two independently operable deep drawing stations. The entire unit can easily process multiple aligners at once. Based on identifying the appropriate aligner shell material for the appropriate model, confusion between processing parameters cannot occur, and additional complexity does not lead to more errors or failures.
[0042] Further details, features, and advantages of the subject matter of the present invention will become apparent from the dependent claims and the description of the drawings below. The drawings are shown below. Figure 1: Schematic diagram of possible process steps according to the present invention Figure 2: Schematic diagram of a possible system according to the present invention Figure 3: Schematic diagram of a possible system according to the present invention Figure 4: Schematic diagram of the system according to the present invention Figure 5: Schematic diagram of the system according to the present invention Figure 6: Schematic diagram of the system according to the present invention
[0043] Figure 1 shows a possible process for manufacturing an orthodontic aligner set according to the present invention. In the first process step a), at least two different physical dental models 1 are provided. Model 1 represents the desired future tooth arrangement in the patient's jaw, and the dental model includes at least a base plate and a dentition configuration on the base plate. In addition to teeth, Model 1 may also include the gums or other features of the patient's oral cavity. The base plate may be flat on the lower side and may further include patient-specific features on the upper side, with the teeth positioned on the upper side. Each Model 1 includes a unique identifier 2, the identifier 2 includes information that codes at least a specific patient and the aligner shell material 3. In process step b), the Models 1 are placed sequentially or in parallel in a deep-drawn chamber 4. Between the process step of providing the Models 1 and the process step of placing the Models 1 in the chamber 4, the identifier 2 is accessed or read from the Models 1. This may be performed in a separate step c), or this step may be performed before or concurrently with placing the Models 1 in the chamber 4. Information accessed and coded with respect to at least the aligner shell material 3 is presented in this step. In process step d), a specific aligner shell material 3, represented by the information coded in process step c), is selected, for example, from the aligner shell material storage location. In step e), the selected aligner shell material 3 is placed on the physical dental model 1, and the aligner foil or sheet is processed by deep drawing. Processing may include heating of the aligner shell material 3, which is performed before, during, or after the placement of the selected aligner shell material 3, to deep draw the aligner shell material 3 onto the physical dental model 1 to produce a single orthodontic aligner. After the aligner shell has been deep drawn onto the physical model 1, in process step f), the processed aligner is removed from the dental model 1, and the orthodontic aligner is removed from the deep drawing chamber. This sequence is performed at least n times, where n is a natural number greater than 1, and in each iteration, at least processes b) through f) are repeated until each physical dental model in the set has been processed.
[0044] Figure 2 shows a preferred embodiment of a system for manufacturing a set of orthodontic aligners according to the present invention. This figure shows a process for processing three different aligners simultaneously. In the first step, different physical dental models 1 are provided. Each physical dental model 1 includes a unique identifier 2, the identifier 2 including information about a specific aligner shell material 3 for at least this particular physical dental model 1. The identifier is read, for example, by a camera, and the specific aligner shell material 3 for this model 1 is displayed, for example, on a screen. The specific aligner shell material 3 is selected from a storage container, heated as necessary, placed on the physical dental model 1, and deep-drawn. Multiple different aligners can be manufactured in one array, and different aligners can be formed from specific different shell materials 3. It is possible to manufacture stepwise aligners simultaneously, and the aligners may exhibit different physical properties depending on the shell material 3 or processing. The selection and placement of the aligner shell material 3 can be done manually.
[0045] Figure 3 shows a further possible embodiment of the system for manufacturing a set of orthodontic aligners according to the present invention. Different aligner shell materials 3 may be placed, for example, in a movable storage location. Individual identifiers 2 on the dental model 1 are read, and information regarding the appropriate aligner shell material 3 is presented to the storage system. By moving the storage system, a shell material 3 suitable for the dental model 1 at hand can be selected. The shell material 3 is heated and placed on the dental model 1 in a deep-drawing chamber 4. Alternatively, the shell material may be placed on the dental model 1, and the shell material 3 may be heated in this position in the deep-drawing chamber 4. The heated shell material 3 is deep-drawn on the dental model 1 to form an aligner. In this figure, three separate deep-drawing locations 5 are located within the same deep-drawing chamber 4. The aligner can be removed from the model 1 and further processed as needed.
[0046] Figure 4 shows a further possible system for manufacturing an orthodontic aligner set according to the present invention. In this process, the selection and placement of the aligner shell material 3 is performed by a robotic arm 6. Different aligner shell materials 3 are stored in different storage locations. Based on coded information on a physical model 1, the robotic arm 6 selects the appropriate material and places the shell material 3 on the appropriate dental model 1. The shell material 3 is deep-drawn to form the aligner. This process procedure enables parallel and safe manufacturing of aligners with different physical properties based on different shell materials 3.
[0047] Figure 5 shows a further possible system for manufacturing an orthodontic aligner set according to the present invention. In this system, the selection and placement of aligner shell material 3 is performed by an automated placement unit 7. The automated placement unit 7 is configured to retrieve aligner shell material 3 from a material-specific storage cabinet 8. Different aligner shell materials 3 are stored in different storage locations within the material-specific storage cabinet 8. Based on coded information on a physical model 1, the automated placement unit 7 selects the appropriate material and places the aligner shell material 3 on the appropriate dental model 1. The shell material 3 is automatically heated to an appropriate temperature before being placed on the model. The heated aligner shell material 3 is deep-drawn to form the aligner. This process procedure enables the automated, parallel, and safe manufacturing of aligners with different physical properties based on different aligner shell materials 3.
[0048] Figure 6 shows a further possible system for manufacturing an orthodontic aligner set according to the present invention. In this system, different aligner shell materials 3 are stored in different storage locations within a material-specific storage cabinet 8. The material-specific storage cabinet 8 is movable, and the appropriate aligner shell material 3 for a particular dental model 1 is introduced into the process by moving the cabinet. Individual identifiers 2 on the dental model 1 are read, and information regarding the appropriate aligner shell material 3 is presented to the storage system. By moving the storage system 8, the appropriate shell material 3 for the dental model 1 at hand is selected. The dental model 1 is placed, for example, on a rondel, and the aligner shell material 3 is placed on top of the dental model 1. In this case, a rondel can be used because the dimensional requirements of the processing system are kept low. The rondel portion is moved to a second position, where the aligner shell material 3 is heated. After heating the aligner shell material 3, the heated aligner shell material 3 is deep-drawn in a third rondel position. Very high-speed processing is possible because the different stations are very close together. The overall spatial dimensions of the machine are very small, allowing for high throughput. Such a system is highly safe because each dental model 1 is equipped with an individual identifier 2 that is involved in at least the selection of the appropriate aligner shell material 3. In addition to the appropriate aligner shell material 3, further processing information such as heating cycles, deep drawing parameters, and special post-treatments can also be included in the identifier 2. Such a system configuration enables automated, cost-effective, and safe processing of various aligner shells. [Explanation of Symbols]
[0049] 1 Dental Model 2. Identifiers 3. Aligner shell material 4 Deep drawing chamber 5 Deep Drawing Station 6. Robot Arm 7 Automatic placement unit 8. Storage System
Claims
1. A method for manufacturing an orthodontic aligner set comprising at least two aligners made of different aligner shell materials (3), a) To provide at least two different physical dental models (1), wherein the dental model (1) includes a base plate and a dentition configuration thereon, the dentition configuration defining at least a portion of the patient's current or future dentition configuration, and each model includes an individual identifier (2), the identifier (2) including information encoding at least a specific patient and aligner shell material (3); b) Placing at least one of the physical dental models (1) provided in step a) into the deep drawing chamber (4); c) Read the individual identifier (2) on the physical dental model (1) and provide coded information relating at least to the aligner shell material, wherein the reading is performed after step a) and before step d); d) Selecting a specific aligner shell material (3) represented by the coded information in step c); e) Placing the selected aligner shell material (3) onto a physical dental model (1), heating the aligner shell material (3) before, during, or after placement of the selected aligner shell material (3), and deep drawing the aligner shell material (3) onto the physical dental model (1) to manufacture a single orthodontic aligner; f) Removing the dental model (1) and orthodontic aligners from the deep-drawn chamber (4); g) A manufacturing method comprising repeating steps b) through f) until each physical dental model (1) of the set has been processed.
2. The manufacturing method according to claim 1, wherein the individual identifier (2) is placed under the bottom plate of the physical dental model (1).
3. The manufacturing method according to claim 1, wherein the individual identifier (2) is placed on a molar represented by a physical dental model (1).
4. The manufacturing method according to any one of claims 1 to 3, wherein in step e), the selected aligner shell material (3) is selected manually or automatically and placed on a physical dental model (1).
5. In step e), the selected aligner shell material (3) is automatically placed on the physical dental model (1). The manufacturing method according to claim 4, wherein in step d), the selection of the aligner shell material (3) includes transferring a specific aligner shell material (3) from a material-specific storage to a deep drawing chamber (4) and onto a physical dental model (1) by a robotic arm (6) according to the provided coded aligner shell material information.
6. The manufacturing method according to any one of claims 1 to 5, wherein step f) includes attaching individual tags to the orthodontic aligner after deep drawing and before removing the orthodontic aligner from the deep drawing chamber (4).
7. The deep drawing chamber (4) includes at least two individually controllable deep drawing stations (5), Steps b) through f) are performed simultaneously on different physical dental models (1). The manufacturing method according to any one of claims 1 to 6, wherein in step e), the same or different aligner shell materials (3) are arranged.
8. The manufacturing method according to claim 7, wherein simultaneous processing on different dental models (1) is performed automatically, comprising at least the automatic selection and transfer of a specific aligner shell material (3) from a material storage unit (8) to a deep drawing station (5) and onto different physical dental models (1) by a robotic arm (6) according to presented and coded aligner shell material information.
9. The manufacturing method according to any one of claims 1 to 8, wherein the physical dental model (1) is a physical dental model (1) obtained by a 3D printing process, the 3D printing process generates one or more support structures that support the physical dental model (1) and the mechanical stability of the 3D printed physical dental model (1), and the individual identifier (2) is attached to or incorporated into the support structure.
10. A system for manufacturing an aligner set including one or more types of orthodontic aligners, wherein the system includes at least the following: i) A physical dental model assembly unit, wherein the model assembly unit is configured to continuously assemble one or more dental models (1), each including at least a base plate and a dentition configuration thereon; ii) An identification unit, wherein the identification unit is configured to apply at least one identifier (2) onto a physical dental model (1), the identifier (2) includes information that codes at least a specific patient and aligner shell material (3); iii) A deep drawing chamber (4) configured to evaluate identifiers (2) on a physical dental model (1), present coded aligner shell material (3) obtained from the identifiers (2), and deep draw the aligner shell material (3) onto the physical dental model (1) at a deep drawing station (5) to obtain an orthodontic aligner; iv) A disassembly unit configured to disassemble an orthodontic aligner from a physical dental model.
11. The system according to claim 10, wherein the identification unit is configured to apply at least one identifier (2) below the base plate.
12. The deep-relief chamber (4) includes a camera unit, The system according to any one of claims 10 to 11, wherein the camera unit is configured to evaluate an identifier (2) from beneath the base plate of a physical dental model (1) and to present information relating to at least the aligner shell material (3).
13. The system includes a computer unit and an automatic aligner shell material supply unit. The computer unit is configured to receive information about the aligner shell material (3) from the camera unit. The system according to claim 12, wherein the automated aligner shell material supply unit is configured to receive information about aligner shell material (3) from a computer unit, select coded aligner shell material (3) from storage, and place aligner shell material (3) in a deep drawing chamber (4) on a physical dental model.
14. The system includes a tagging unit, The system according to any one of claims 10 to 13, wherein the tagging unit is configured to apply individual tags to orthodontic aligners after deep drawing.
15. The system according to any one of claims 10 to 14, wherein the deep drawing chamber (4) includes at least two independently operable deep drawing stations (5).