Method for manufacturing oral implant material

Abstract

To provide a method for manufacturing an oral implant material.SOLUTION: A method for manufacturing an oral implant material includes the steps of: printing a tooth root part to a plurality of standard metal ingots using a metal material to obtain a metal base; and printing an alveolus restorative material 5 around the metal base, where the selective laser melting process is used to print a tooth root part and molten deposition process is used to print an alveolus restorative material. The present invention manufactures implant materials for a plurality of patients at the same time with one-time printing.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to the technical field of additive manufacturing, and in particular to a method for manufacturing oral implant materials. [Background technology]

[0002] The production of oral implant materials is one of the current application directions of additive manufacturing technology, and additive manufacturing technology will become even more important as dental implant technology develops in the direction of "immediate implant", and standard cylindrical implant roots begin to be replaced by bionic roots.

[0003] The processes disclosed in the prior art require the manufacture of implants for each patient, and the entire process from modeling to manufacturing is carried out individually, which is relatively labor-intensive and time-consuming, making it difficult to meet the timely requirement of "immediate implants." Furthermore, because tooth roots are made of metal, when there is a large alveolar bone defect, the limitations of metal materials mean that simply increasing the tooth root cannot satisfy the filling and growth of the alveolar bone. While prior art such as CN106137421B provides the ability to arrange a honeycomb structure, the number of patients for whom this physical improvement is suitable and the improvement effects that can be achieved are limited. Summary of the Invention

[0004] To solve the problems in the background art, the present invention provides a method for producing an oral implant material.

[0005] The object of the present invention is achieved by the following technical solutions:

[0006] 1. A method for manufacturing an oral implant material, comprising: printing a plurality of dental roots onto a plurality of standard metal ingots by a selective laser melting process to obtain a plurality of metal bases; and printing an alveolar restorative material around at least one of the metal bases by a fused deposition process, Step S1 of preparing a removable sub-base plate common to the selective laser melting process and the fused deposition process, the removable sub-base plate having pre-formed mounting holes for mounting a plurality of standard metal ingots; Step S2: mounting a plurality of standard metal ingots into mounting holes in a removable sub-base plate, and fixing the removable sub-base plate to a base plate of a selective laser melting apparatus, wherein, after the mounting is completed, the top surfaces of the plurality of standard metal ingots are horizontal and aligned with each other, and all of the plurality of standard metal ingots are higher than the top surface of the removable sub-base plate; Step S3 of pre-filling a powder cylinder of a selective laser melting apparatus with powder, wherein after pre-filling is completed, the top surface of the powder is aligned with the top surfaces of a plurality of standard metal ingots; Step S4: The selective laser melting device uses the top surfaces of a plurality of standard metal ingots as printing references for the first layer, and according to the stacked three-dimensional models, alternately scatters powder on the top surfaces of the plurality of standard metal ingots and performs laser scanning to obtain a plurality of metal bases until each complete tooth root to be printed is obtained, and the three-dimensional models are obtained by three-dimensionally scanning and modeling the teeth and alveolar bone regions of a plurality of patients, and therefore each printed tooth root is different from each other; Step S5 involves printing an alveolar restorative material onto the metal substrate using a fused deposition process on the same removable sub-base plate without removing the metal substrate obtained by printing in step S4 to obtain an oral implant.

[0007] Preferably, in step S2, the plurality of standard metal ingots are 0.5 to 3.0 mm higher than the upper surface of the removable sub-base plate.

[0008] Preferably, in step S5, before printing the alveolar restorative material, no support material is printed and the first layer of alveolar restorative material is supported by a prefabricated spacer.

[0009] Preferably, in step S5, the removable sub-base plate is not removed, and the print head is switched directly to the fused deposition print head of the selective laser melting device by switching the print head.

[0010] Preferably, in step S5, the detachable sub-base plate is removed from the base plate of the selective laser melting apparatus and then attached to the base plate of the fused deposition apparatus.

[0011] Preferably, the standard metal ingot is a cast ingot, a machined ingot, or a powder metallurgy ingot.

[0012] The beneficial effects are as follows:

[0013] The present invention introduces a standard ingot into the production of a metal substrate and compositely prints alveolar repair materials onto the metal substrate, thereby realizing the rapid production of multiple implant materials and simultaneously improving the biocompatibility of the implant materials with the human body. The present invention optimizes the printing process by attaching a standard metal ingot to the mounting holes of a removable sub-base plate in cooperation with height design means and level adjustment means, reducing or avoiding the need for a hanging structure, and reducing the design workload, operation workload, and costs of the entire process. [Brief explanation of the drawings]

[0014] [Figure 1] This is state 1 of the process of the present invention. [Figure 2] This is state 2 of the process of the present invention. [Figure 3] This is state 3 of the process of the present invention. [Figure 4] This is state 4 of the process of the present invention. [Figure 5] This is state 5 of the process of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] This method for manufacturing an oral implant material involves printing a plurality of tooth root portions using a metal material on a plurality of standard metal ingots 1 prepared in advance to obtain a plurality of metal bases, and printing an alveolar repair material 5 around at least one of the metal bases to obtain the oral implant material.

[0016] In this specification, "plurality" is determined based on the processing capacity and order integration capacity of the equipment, and may be, for example, 3 to 12.

[0017] The present invention establishes a universal abutment standard part based on the analysis of medical three-dimensional models of different patients, and produces a standard metal ingot 1 by traditional methods (casting, machining, or powder metallurgy). The additive manufacturing process does not take much time, and multiple different products can be produced quickly at the same time. Multiple different products can be printed and scanned in a single printing and scanning process of the printing device, reducing waste of space and time on the device. Different implant materials can be produced for multiple patients simultaneously in a single printing run.

[0018] If the alveolar bone defect space is large, the alveolar repair material 5 is printed around the metal base.

[0019] Although polymeric materials and polymer-based composite materials are considered as alveolar restorative materials, these materials are more effective in terms of absorption and fusion with the alveolar bone. They have a low melting point, require less printing atmosphere, and are manufactured using three-dimensional deposition methods, which overcomes the limitations of metal materials in many aspects. They not only meet the clinical requirements of filling and growing the alveolar bone, but are also easy to manufacture.

[0020] 1 to 5 show the principle of the method for manufacturing an oral implant material provided by an embodiment of the present invention in several different process states.

[0021] In step S1, a removable sub-base plate 2 common to the selective laser melting process and the fused deposition process is prepared, and the removable sub-base plate 2 is pre-drilled with mounting holes for mounting a plurality of standard metal ingots 1.

[0022] In step S2, the order in which multiple standard metal ingots 1 are attached to the attachment holes of the removable sub-base plate 2 and the removable sub-base plate 2 is fixed to the base plate 3 of the selective laser melting apparatus does not matter. After the attachment is completed, the top surfaces of the multiple standard metal ingots 1 are horizontal and aligned with each other.

[0023] By mounting the standard metal ingot 1 on the removable sub-base plate 2, no modification or damage is caused to the base plate 3, the standard metal ingot 1 is easily mounted in the mounting hole of the removable sub-base plate 2, and height and level adjustments are convenient, thereby avoiding cutting of the printed product and subsequent polishing.

[0024] As can be seen from the drawing, the multiple standard metal ingots 1 are positioned a certain distance above the upper surface of the removable sub-base plate 2. This distance not only makes it convenient to remove the products, but also makes it easy to self-adjust the horizontal accuracy using the first few layers of powder scanning molding if horizontal deviation occurs due to installation accuracy. This distance can be 0.5 to 3.0 mm, preferably 1 to 2 mm.

[0025] In step S3, powder is pre-filled into the powder cylinder of the selective laser melting device, and after the pre-filling is completed, the top surface of the powder is aligned with the top surface of multiple standard metal ingots 1, and this process is for performing the subsequent layer-by-layer powder scattering and scanning operation by selective laser melting, but since it is a basic operation, it is not shown in the drawing.

[0026] In step S4, the selective laser melting device uses the top surfaces of multiple standard metal ingots 1 as printing references for the first layer. According to the stacked three-dimensional model, powder is alternately scattered on the top surfaces of the multiple standard metal ingots 1 and laser scanned to obtain multiple metal bases until each complete tooth root to be printed is obtained. The three-dimensional model in this specification was obtained by three-dimensionally scanning and modeling the teeth and alveolar bone regions of multiple patients. Therefore, each printed tooth root is different from each other and represents the actual shape of the tooth root of multiple patients. Figures 2 and 3 show the state of the tooth root during and after printing, respectively. For ease of illustration, the powder cylinder and print head are omitted.

[0027] The multiple standard metal ingots 1 of the present invention may be identical or different, for example, they may have different outer dimensions but the same height, or they may have different outer dimensions and heights but the same height and flush top surfaces after being attached to the mounting holes of the removable sub-base plate 2.

[0028] In this embodiment, the standard metal ingot 1 and the tooth root are preferably made of a titanium alloy material, but the standard metal ingot 1 and the tooth root that form the same metal substrate may be made of different metals.

[0029] The advantage of the synchronous printing of multiple tooth root sections of the present invention is that it not only improves the efficiency of removal, installation and manufacturing, but also plays a very important role in controlling the quality of the printed metal base. An infrared thermometer can be used to measure the surface temperature of each tooth root section at any time during printing, and the laser scan head is controlled to scan a new printing layer at each tooth root section only when the temperature of each tooth root section does not exceed the system's preset temperature range, thereby preventing the accumulation of thermal stress. Using the synchronous printing method of the present invention, the system can collect the surface temperature of each tooth root section and automatically schedule the scanning order of each layer according to the collected temperature, thereby shortening waiting time and suppressing internal micro-defects.

[0030] In step S5, as shown in Figures 4 and 5, an alveolar restorative material 5 is printed onto the metal base of the same removable sub-base plate 2 using a fused deposition process without removing the metal base obtained by printing in step S4 to obtain an oral implant.

[0031] According to the three-dimensional model obtained in advance, the alveolar restorative material 5 may not necessarily be printed on all of the metal substrates as shown in the figure, and printing may not be necessary on some of the metal substrates.

[0032] In one example, the additive manufacturing device adds a fused deposition printing head to a selective laser melting device, where the fused deposition printing head has the functions of supplying and melting material (filament / powder), directly utilizing the three-dimensional motion system of the selective laser melting device and alternating with the laser scanning head. In this case, in step S5, the detachable sub-base plate 2 cannot be removed, and the printing head is directly switched to the fused deposition printing head of the selective laser melting device by switching the printing head.

[0033] In another example, the selective laser melting apparatus and the fusion deposition apparatus are separate apparatuses, in which case the second printing stage can be completed by removing the detachable sub-base plate 2 from the base plate 3 of the selective laser melting apparatus and then attaching it to the base plate of the fusion deposition apparatus. In this case, a standard metal ingot 1 is attached to the detachable sub-base plate 2, which reduces the workload of repeatedly removing, attaching, and adjusting the horizontal state of the semi-finished product when performing two different printing methods, and reduces the difficulty of operation.

[0034] A very significant effect of this embodiment is that the printing direction is changed to a printing direction from the base. Both the root portion and the alveolar repair material 5 have a structure that is narrow at the bottom and wide at the top. If printing in the forward direction, a support material must be printed at the same time to complete the hanging area, which is difficult to form. The printing direction of this embodiment not only ensures that the root portion basically or completely does not have a hanging structure, but also that the alveolar repair material 5 printed thereafter basically or completely does not have a hanging structure. Therefore, there is no need to add printing support material throughout the entire printing process, which again reduces the design work, operation work, and cost of the printing process from modeling to material preparation.

[0035] The basic printing surface configuration for printing the alveolar repair material 5 can be seen in Figure 4. In step S5, before printing the alveolar repair material 5, no support material is printed. Instead, the first layer of alveolar repair material 5 is supported by a prefabricated spacer 4 prepared in advance, further improving manufacturing efficiency. The prefabricated spacer 4 can be made of a material that can be easily separated from the polymer material (such as a ceramic sheet). Alternatively, a simple metal sheet can be used, with a layer of material that can be easily separated from the polymer material or a sacrificial material layer typically used for printing support materials provided on its upper surface. Preferably, the metal sheet is used to coat the sacrificial material layer. The metal sheet can be cut into two interlocking halves that fit together to surround a standard metal ingot 1. [Explanation of symbols]

[0036] 1- Standard Metal Ingot 2- Removable sub-baseplates 3-Base Plate 4-Prefabricated Spacers 5-Alveolar restorative materials

Claims

1. 1. A method for manufacturing an oral implant material, comprising printing a plurality of dental roots onto a plurality of standard metal ingots (1) by a selective laser melting process to obtain a plurality of metal bases, and printing an alveolar restorative material (5) around at least one of the metal bases by a fused deposition process, Step S1: preparing a removable sub-base plate (2) common to the selective laser melting process and the fused deposition process, the removable sub-base plate (2) having pre-formed mounting holes for mounting a plurality of standard metal ingots (1); Step S2: mounting a plurality of standard metal ingots (1) in mounting holes in a removable sub-base plate (2), and fixing the removable sub-base plate (2) to a base plate (3) of a selective laser melting device, whereby after the mounting is completed, the top surfaces of the plurality of standard metal ingots (1) are horizontal and aligned with each other, and all of the plurality of standard metal ingots (1) are higher than the top surface of the removable sub-base plate (2); Step S3: pre-filling powder into a powder cylinder of a selective laser melting device, where after pre-filling is completed, the top surface of the powder is aligned with the top surfaces of a plurality of standard metal ingots (1); Step S4: The selective laser melting device uses the upper surfaces of a plurality of standard metal ingots (1) as a printing reference for the first layer, and according to the stacked three-dimensional model, alternately scatters powder on the upper surfaces of the plurality of standard metal ingots (1) and performs laser scanning to obtain a plurality of metal bases until each complete tooth root to be printed is obtained, and the three-dimensional model is obtained by three-dimensionally scanning and modeling the teeth and alveolar bone regions of a plurality of patients, and therefore each printed tooth root is different from each other; Step S5: printing an alveolar restorative material (5) onto the metal substrate using a fused deposition process on the same removable sub-base plate (2) without removing the metal substrate printed in step S4 to obtain an oral implant. A method for producing an oral implant material, comprising:

2. The method for manufacturing an oral implant material according to claim 1, characterized in that in step S2, the plurality of standard metal ingots (1) are 0.5 to 3.0 mm higher than the upper surface of the removable sub-base plate (2).

3. 2. The method for producing an oral implant material according to claim 1, characterized in that in step S5, before printing the alveolar restorative material (5), no support material is printed, and the first layer of alveolar restorative material (5) is supported by a prefabricated spacer (4).

4. 2. The method for manufacturing an oral implant material according to claim 1, characterized in that in step S5, the removable sub-base plate (2) cannot be removed, and the printing head is directly switched to the fusion deposition printing head of the selective laser melting device by switching the printing head.

5. 2. The method for manufacturing an oral implant material according to claim 1, wherein in step S5, the detachable sub-base plate (2) is removed from the base plate (3) of the selective laser melting device and then attached to the base plate of the fused deposition device.

6. 2. The method for producing an oral implant material according to claim 1, wherein the standard metal ingot (1) is a cast ingot, a machined ingot, or a powder metallurgy ingot.

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