Systems for and methods of shaping orthodontic archwires

Abstract

Systems for and methods of shaping non-sliding orthodontic archwires. A system with a robot can move connectors of an archwire to positions corresponding to digital markers in a virtual model of a patient's teeth in a planned alignment which can position interproximal segments between adjacent connectors in custom nonplanar shapes. The interproximal segments can be heat set such that the custom nonplanar shapes become the memorized shape of the interproximal segments configured to move a patient's teeth toward the digitally planned alignment.

Description

SYSTEMS FOR AND METHODS OF SHAPING ORTHODONTIC ARCHWIRESINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 556,295, filed February 21, 2024, which is incorporated by reference herein in its entirety. Any and all applications, if any, for which a foreign or domestic priority claim is identified in the Application Data Sheet of the present application is hereby incorporated by reference under 37 CFR 1.57.BACKGROUNDField

[0002] The present disclosure relates in some aspects to systems for and methods of shaping orthodontic appliances such as archwires and in certain aspects to systems for and methods of shaping non-sliding orthodontic archwires.SUMMARY

[0003] Teeth can be moved by bonding orthodontic brackets to the lingual or buccal surfaces of a patient’s teeth and coupling an archwire to the bonded orthodontic brackets. The archwire can exert forces on the brackets using sliding or non-sliding mechanics, which can cause the patient’s teeth to move toward a planned alignment. Custom shaping an archwire to move the patient’s teeth to the planned alignment can be difficult, expensive, and / or time consuming. Disclosed herein are methods and systems for shaping an archwire in a custom 3D shape that at least addresses the foregoing issues. The methods and systems are described in reference to custom 3D shaping a non-sliding archwire but the disclosed methods and systems can be used to custom 3D shape sliding or partially sliding archwires as well.

[0004] A system for custom shaping an archwire to move a patient’ s teeth can include a plurality of holders and a robot (e.g., automated machine, machine) that can custom 3D shape an archwire based on a digital model. For example, the robot can reconfigure (e.g., bend, move, place) an arch wire into a configuration that corresponds to the digital model. The robot can position a connector of an archwire in a custom position based on the digital model while a holder (e.g., fastener, vise, clasp, clamp, gripper) can hold an adjacent connector of the archwire at afixed position. The system can heat set a portion (e.g., interproximal segment, loop) of the archwire connecting the connector held by the robot and the adjacent connector held by the holder so that the relative positioning between the two connectors and / or the positioning of the portion is the memorized (e.g., default, set) configuration. The system can advance the archwire toward the holder and robot to position connectors of the archwire to be accessible by the holder and robot for holding and / or positioning. The system can sequentially position and heat set portions of the archwire until each portion of the archwire has been heat set in a custom position such that the entire archwire has a custom 3D shape for positioning a patient’ s teeth according to a treatment plan based on a digital model.

[0005] In some variants, a system for custom shaping an archwire for orthodontic treatment is disclosed herein. The system can include a system, which can include a robot, that incrementally positions and heat sets portions of an archwire in a custom nonplanar shape, which can include incrementally positioning and heat setting portions of the archwire in the custom nonplanar shape until an entirety of the archwire is in a custom nonplanar shape that corresponds to a digitally planned custom nonplanar shape.

[0006] In some variants, the techniques described herein relate to a system for custom shaping an archwire for orthodontic treatment, the system including: a robot including a tool, the tool configured to move a first connector of the archwire to a position corresponding to a digital marker in a virtual model of a patient's teeth in a planned alignment such that an interproximal segment between the first connector and a second connector of the archwire is in a custom nonplanar shape; and a heating device configured to heat set the interproximal segment such that the custom nonplanar shape is a memorized shape of the interproximal segment.

[0007] In some variants, the techniques described herein relate to a system, further including a holder configured to hold the second connector of the archwire.

[0008] In some variants, the techniques described herein relate to a system, further including an actuator configured to advance the archwire to position the first connector for grasping by the tool of the robot.

[0009] In some variants, the techniques described herein relate to a system, wherein the actuator is configured to advance the archwire to position the second connector of the archwire for holding by the holder.

[0010] In some variants, the techniques described herein relate to a system, wherein the actuator is configured to advance the archwire to position the second connector of the archwire for grasping by the tool of the robot.

[0011] In some variants, the techniques described herein relate to a system, wherein the actuator is configured to advance the archwire to position a third connector of the archwire for holding by a holder.

[0012] In some variants, the techniques described herein relate to a system, wherein the tool is configured to move the second connector of the archwire to a position corresponding to a second digital marker in the virtual model such that a second interproximal segment between the second connector and a third connector of the archwire is in a second custom nonplanar shape, and wherein the heating device is configured to heat set the second interproximal segment such that the second custom nonplanar shape is a memorized shape of the second interproximal segment.

[0013] In some variants, the techniques described herein relate to a method of custom shaping an archwire, the method including: grasping a first connector of an archwire; holding a second connector of the archwire; moving the first connector of the archwire to a position corresponding to a digital marker in a virtual model of a patient's teeth in a planned alignment such that an interproximal segment between the first connector and a second connector of the archwire is in a custom nonplanar shape; and applying energy to the interproximal segment to set the interproximal segment such that the custom nonplanar shape is a memorized shape of the interproximal segment.

[0014] In some variants, the techniques described herein relate to a method, further including advancing the archwire with an actuator to position the first connector for grasping by a tool of a robot.

[0015] In some variants, the techniques described herein relate to a method, further including advancing the archwire with an actuator to position the second connector for grasping by a holder.

[0016] In some variants, the techniques described herein relate to a method, further including: grasping the second connector of the archwire; holding a third connector of the archwire; moving the second connector of the archwire to a position corresponding to a second digital marker in the virtual model of the patient's teeth in the planned alignment such that a second interproximal segment between the second connector and the third connector of thearchwire is in a second custom nonplanar shape; and applying energy to the second interproximal segment to set the second interproximal segment such that the custom nonplanar shape is a memorized shape of the second interproximal segment.

[0017] In some variants, the techniques described herein relate to a system for custom shaping an archwire for orthodontic treatment, the system including: a robot configured to move a first portion of the archwire to a custom nonplanar shape; and a device configured to apply energy to the first portion to set the first portion such that the custom nonplanar shape is a memorized shape of the first portion.

[0018] In some variants, the techniques described herein relate to a system, further including any of the features described in the present application.

[0019] In some variants, the techniques described herein relate to a method of custom shaping an archwire, the method including: grasping a first portion of an archwire; 16. moving the first portion of the archwire to a custom nonplanar shape; and applying energy to the first portion to set the first portion such that the custom nonplanar shape is a memorized shape of the first portion.

[0020] In some variants, the techniques described herein relate to a method of custom shaping an archwire, the method including: grasping a first connector of an archwire; holding a second connector of the archwire, the second connector adjacent to the first connector; moving the first connector to a first digitally planned position relative to the second connector such that a first archwire segment connecting the first and the second connectors is in a first custom nonplanar shape; applying energy to the first archwire segment to set the first archwire segment in the first custom nonplanar shape; grasping the second connector of the archwire; holding a third connector of the archwire, the third connector adjacent the second connector; moving the second connector to a second digitally planned position relative to the third connector such that a second archwire segment connecting the second and the third connectors is in a second custom nonplanar shape; and applying energy to the second archwire segment to set the second archwire segment in the second custom nonplanar shape.

[0021] In some variants, the techniques described herein relate to a method of custom shaping an archwire, the method including: grasping a first connector of an archwire; holding a second connector of the archwire, the second connector adjacent to the first connector; moving the first connector to a first digitally planned position relative to the second connector such that a first archwire segment connecting the first and the second connectors is in a first custom nonplanarshape; and applying energy to the first archwire segment to set the first archwire segment in the first custom nonplanar shape.

[0022] In some variants, the techniques described herein relate to a method, wherein grasping the first connector of the archwire includes grasping the first connector with a gripper of an automated machine.

[0023] In some variants, the techniques described herein relate to a method, wherein the automated machine is a robot.

[0024] In some variants, the techniques described herein relate to a method, wherein grasping the first connector of the archwire includes actuating a gripper to clamp on the first connector.

[0025] In some variants, the techniques described herein relate to a method, wherein the gripper is an actuatable clamp.

[0026] In some variants, the techniques described herein relate to a method, wherein holding the second connector of the archwire includes actuating a clamp to hold the second connector.

[0027] In some variants, the techniques described herein relate to a method of custom shaping an archwire, the method including: moving a first connector of an archwire to a digitally planned position relative to a second connector of the archwire such that an archwire segment connecting the first and the second connectors is in a custom nonplanar shape; and applying energy to the archwire segment to set the archwire segment in the custom nonplanar shape.

[0028] In some variants, the techniques described herein relate to a system for custom shaping an archwire for orthodontic treatment, the system including: a gripper configured to grasp a first connector of an archwire; a clamp configured to hold a second connector of the archwire, the second connector being adj acent the first connector; and an energy application device; wherein the gripper is configured to move the first connector to a digitally planned position relative to the second connector such that a segment of the archwire connecting the first and the second connectors is in a custom nonplanar shape; and wherein the energy application device is configured to apply energy to the archwire segment to set the archwire segment in the custom nonplanar shape.

[0029] In some variants, the techniques described herein relate to a system, wherein the energy application device includes a heat gun, the heat gun configured to apply heat to the archwire segment.

[0030] In some variants, the techniques described herein relate to a system, wherein the energy application device includes an electrode, the electrode configured to apply electrical energy to the archwire segment.

[0031] In some variants, the techniques described herein relate to a system, wherein the gripper is automated.

[0032] In some variants, the techniques described herein relate to a system, wherein the clamp is automated.

[0033] In some variants, the techniques described herein relate to a system, further including a robot, the robot including the gripper.

[0034] In some variants, the techniques described herein relate to a system, further including a second clamp configured to hold the archwire and deliver the second connector to the clamp.

[0035] In some variants, the techniques described herein relate to a system, wherein the second clamp is configured to be advanced from a loading location to deliver the second connector to the clamp.

[0036] In some variants, the techniques described herein relate to a system, wherein the second clamp is configured to be advanced to deliver a third connector, adjacent the second connector, to the clamp after the energy application device applies energy to the archwire segment.

[0037] In some variants, the techniques described herein relate to a system, wherein the gripper is configured to grasp the second connector after the second clamp delivers the third connector to the clamp.

[0038] In some variants, the techniques described herein relate to a system, further including a vision system configured to collect visual data regarding the archwire to guide actions by the system.

[0039] In some variants, the techniques described herein relate to a system, further including a third clamp configured to receive the archwire from an operator during a loading procedure.

[0040] In some variants, the techniques described herein relate to a system, further including a second vision system configured to determine if the archwire is properly received by the third clamp.

[0041] In some variants, the techniques described herein relate to a system for custom shaping an archwire for orthodontic treatment, the system including: an automated gripper configured to grasp a first connector of an archwire; a first automated clamp configured to hold a second connector of the archwire, the second connecting being adjacent the first connector; a second automated clamp configured to support the archwire, the second automated clamp configured to be linearly translated while holding the portion of the archwire to position the archwire to be held by the first automated clamp; an energy application device; wherein the automated gripper is configured to move the first connector to a digitally planned position relative to the second connector such that a segment of the archwire connecting the first and the second connectors is in a custom nonplanar shape; and wherein the energy application device is configured to apply energy to the archwire segment to set the archwire segment in the custom nonplanar shape.BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Various embodiments are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the embodiments. Various features of different disclosed embodiments can be combined to form additional embodiments, which are part of this disclosure.

[0043] FIG. 1A illustrates an archwire.

[0044] FIG. IB illustrates a connector of the archwire.

[0045] FIG. 1C illustrates the archwire with a custom shape corresponding to a planned alignment of a patient’s teeth.

[0046] FIG. 2 illustrates an orthodontic bracket.

[0047] FIG. 3 illustrates the connector of the archwire coupled to the orthodontic bracket.

[0048] FIG. 4A illustrates another archwire.

[0049] FIG. 4B illustrates another archwire.

[0050] FIGS. 5A and 5B illustrates a system for custom shaping an archwire.

[0051] FIG. 6 illustrates a block diagram of a system including a scanning device, design system, shaping system, and / or clinician system.

[0052] FIG. 7 illustrates a method of developing and communicating a virtual model of a patient’s teeth for a treatment plan.

[0053] FIG. 8 illustrates a method of custom shaping an archwire.

[0054] FIG. 9A illustrates a system for custom shaping an archwire in a housing.

[0055] FIG. 9B illustrates the system of Claim 9A with doors of the housing removed to show components of the system.

[0056] FIG. 10 illustrates the system of FIGS. 9A and 9B.

[0057] FIG. 11 illustrates another view of certain components of the system of FIGS.9 A and 9B.

[0058] FIG. 12 illustrates a first holder of the system of FIG. 10 that can hold the archwire during a setup process.

[0059] FIG. 13 illustrates the archwire received by the first holder of the system of FIG. 10.

[0060] FIG. 14A illustrates the archwire held by the first holder and a second holder of the system of FIG. 10.

[0061] FIG. 14B illustrates the archwire with a feature utilized by a vision system to determine if the archwire is correctly loaded into the first holder.

[0062] FIG. 15 illustrates a vision system of the system of FIG. 10 capturing data regarding the archwire held by the first and second holders.

[0063] FIG. 16 illustrates the second holder of the system of FIG. 10 moved to position the archwire to be grasped by a third holder of the system.

[0064] FIG. 17 illustrates a fourth holder of a robot (e.g., machine) of the system of FIG. 10 holding a connector of the archwire and the third holder of the system holding an adjacent connector.

[0065] FIG. 18 illustrates an enlarged view of the fourth holder of the robot of FIG. 17 holding a connector of the archwire and the third holder holding an adjacent connector such that the robot can reposition the connector relative to the adjacent connect according to a digital model.

[0066] FIG. 19 illustrates an archwire that has been custom shaped by the system of FIG. 10 disposed on a tray.DETAILED DESCRIPTION

[0067] Malocclusion of the teeth can be treated using orthodontic brackets and archwires to move the patient’s teeth using sliding or non-sliding mechanics. For example, scans of a patient’s teeth can be taken and a digital model (e.g., virtual model) of the patient’s teeth can be created, at least in part, from the scans. The teeth of the digital model can be moved from positions of malocclusion (e.g., first positions) to second positions, which can be a planned alignment of the teeth (e.g., final planned alignment of the teeth). Digital brackets can be placed, respectively, on the lingual or buccal surfaces of the teeth in the digital model. In some variants, the digital brackets can be placed before moving the teeth of the digital model from the positions of malocclusion (e.g., first positions) to the second positions (e.g., planned alignment). The positions of the digital brackets on the teeth of the digital model in the second positions can correspond to a custom shape of an archwire that can move the patient’s teeth from the first positions of malocclusion to the second positions. For example, digital markers can be positioned on and / or in the digital brackets to indicate positions for connectors of the archwire with the archwire in a custom 3D shape that can move the patient’ s teeth to the second positions. In some variants, the digital brackets can include features to indicate placement of the digital markers. In some variants, a software program can automatically place the digital markers on and / or in the digital brackets. In some variants, the digital brackets can include digital markers. In some variants, no digital brackets are used and the positions of the teeth in the digital model can correspond to a custom shape of an archwire that can move the patient’s teeth from the first positions to the second positions. For example, the digital markers can be positioned on and / or proximate the digital teeth in the digital model without digital brackets.

[0068] A system can include a robot (e.g., machine, automated machine) that can custom 3D shape an archwire based on the digital model. For example, the robot can reconfigure (e.g., bend, move, place) an archwire into a configuration that corresponds to a configuration of digital markers in the digital model (e.g., digital markers disposed on and / or in digital brackets in the digital model). As described herein, each digital marker can correspond to a connector of the archwire. In some variants, the system can incrementally custom shape the archwire by placing connectors of the archwire in configurations that correspond to the configurations of the digital markers (e.g., coordinates) in the digital model. For example, the system can include a holder (e.g., fastener, vise, clasp, clamp) that can hold one connector of the archwire while the robot positions an adjacent connector of the archwire in a custom position (e.g., orientation) based onthe position of a corresponding digital marker in the digital model. The system can heat set the portion (e.g., interproximal segment, loop) of the archwire between the one connector of the archwire held by the holder and the adjacent connector of the archwire so that relative positioning between the one connector and the adjacent connector is the memorized (e.g., default) configuration. In some variants, the system can be used to custom 3D shape an archwire based on the positioning of digital markers on digital teeth in the digital model without digital brackets. In some variants, a digital archwire can be designed in the digital model with the teeth of the digital model in the second positions and the system can custom shape the archwire based on the digital archwire. In some variants, the system and / or digital model can compensate for material characteristics of the archwire. For example, the forces exerted by the archwire to move the patient’s teeth toward the second positions can decrease as the patient’s teeth get closer to the second positions to the extent that, if not taken into account, the archwire can be unable to completely move the patient’s teeth to the second positions. Accordingly, the archwire can be custom 3D shaped to compensate for these decreasing forces. For example, absent the reactionary forces of the patient’s teeth in the second positions, connectors of the custom-shaped archwire can be positioned beyond the positions of the corresponding digital markers, digital brackets, and / or digital teeth of the digital model in the planned alignment to compensate for the decreasing forces applied by the archwire as the patient’s teeth move.

[0069] The archwire, which can also be referred to as an archform, can be made of a shape memory material, such as a shape memory alloy (e g., nickel -titanium alloy such as Nitinol) and / or a shape memory polymer. The archwire can be cut (e.g., laser, waterjet, plasma cut, punching, etc.) from a sheet of material (e.g., shape memory material). In some variants, the archwire can be cut from a sheet of material by the system and then custom shaped. In some variants, the archwire can be cut and simultaneously custom shaped by the system. In some variants, the archwire can be cut and then immediately custom shaped by the system. The archwire can be custom cut, which can include omitting a connector due to a missing tooth, including custom shaped and / or sized loops to address a patient’s unique anatomy, etc. In some variants, the archwire can be bent with a wire bender, which can include bending a wire of material (e.g., shape memory material).

[0070] The archwire can include connectors (e.g., bracket connectors, anchors) that can be coupled to brackets or bonded directly to teeth and interproximal segments (e.g., interproximal loops) that can be disposed between connectors to move one or more teeth of thepatient. When cut from the sheet of material, the archwire can have a substantially flat two- dimensional shape and / or otherwise planar shape. When wire is bent with a wire bender to form an archwire, the archwire can have a substantially flat two-dimensional shape and / or otherwise planar shape. The archwire can then be deflected from the two-dimensional shape to a custom nonplanar shape that corresponds to a digital treatment plan. For example, as detailed herein, the system can hold one connector in place while the robot of the system moves an adjacent connector to a position that corresponds to a position of a digital marker in a digital model of the patient’s teeth. With the connectors held in position, the system can heat set the portion (e.g., interproximal segment, loop) of the archwire between the connectors. The setting of the portion of the archwire can be accomplished by way of exposure to energy from a heating device, such as a heat gun, electrode, and / or other suitable devices. In some variants, electrical current can be applied to the portion of the archwire to set the portion of the archwire in the custom nonplanar shape. Setting the portion of the archwire can set a new default (e.g., memorized) shape for the portion and / or adjacent connectors of the archwire such that the portion and / or adjacent connectors of the archwire are biased toward the default shape when moved (e.g., deflected) therefrom. Accordingly, if the portion of the archwire is deflected from the memorized custom nonplanar shape, the portion of the archwire can exert forces to return the portion of the archwire back to the memorized custom nonplanar shape. After heat setting the portion of the archwire, the adjacent portion of the archwire can be custom shaped. For example, the connector that was previously held by the holder can be moved by the robot to a position that corresponds to a position of a digital marker in a digital model of the patient’s teeth while a third connector of the archwire is held by the holder. The adjacent portion can then be heat set. The system can proceed to custom shape and heat set the entirety of the archwire by incrementally shaping and heat setting portions and / or connectors of the archwire as described herein.

[0071] An indirect bonding (IDB) tray can be formed based on the digital model. The teeth of the digital model, with the digital brackets disposed thereon, can be returned back to the positions of malocclusion that can reflect the current positions of the patient’s teeth. In some variants, the IDB tray can be formed based on the digital model with digital brackets placed on the maloccluded teeth of the digital model prior to movement of the teeth to the second positions. An IDB tray can be 3D printed based on the digital model and / or over molded on a physical model of the patient’s teeth. The IDB tray can be sized and shaped to fit over the teeth of the patient. The IDB tray can include wells (e.g., pockets, recesses, etc.) that can house orthodontic bracketstherein. The wells can be positioned based on the corresponding positioning of the digital brackets in the digital model. The IDB tray can correspond to a single tooth of the patient, a portion of a dental arch, or an entirety of a dental arch.

[0072] Orthodontic brackets can be placed in respective wells of the IDB tray with contact surfaces (e.g., bonding surfaces) exposed. An adhesive can be applied to the contact surfaces and the loaded IDB tray can be placed over the teeth of the patient, positioning the orthodontic brackets at locations on the teeth of the patient that correspond to the positioning of the digital brackets on the teeth in the digital model in the first positions. The orthodontic brackets can be bonded to the teeth of the patient, which can be facilitated by exposing the adhesive to air, light (e.g., UV light), heat, low temperatures, and / or chemical(s).

[0073] With the orthodontic brackets bonded to the teeth of the patient, the custom shaped archwire can be moved (e.g., deflected) from the custom 3D shape and coupled to the bonded orthodontic brackets. The connectors of the archwire can be coupled, e.g., locked, to the bonded orthodontic brackets such that the archwire does not slide with respect to the brackets. As described herein, the deflected archwire can exert forces on the teeth of the patient as the archwire exerts forces to move back toward the custom 3D shape (e.g., undeflected position, memorized custom nonplanar shape), which can move the teeth of the patient, using non-sliding mechanics, toward seconds positions that correspond to the second positions of the teeth in the digital model (e.g., planned alignment of the teeth). In some variants, the archwire can be deflected from the custom shape and bonded directly to the patient’s teeth, including buccal or lingual surfaces.

[0074] In some variants, a series of archwires can be sequentially installed in the patient’s mouth (e.g., coupled to the brackets) and replaced to move the patient’s teeth from positions of malocclusion to the second positions. For example, an initial archwire set in the custom nonplanar shape can be used for an initial stage of treatment for initially moving the teeth of the patient toward the second positions. An intermediate archwire set in the custom nonplanar shape, which can be stiffer than the initial archwire, can be used for an intermediate stage of treatment for moving the teeth of the patient closer toward the second positions. A final archwire set in the custom nonplanar shape, which can be stiffer than the intermediate archwire, can be used for a final stage of treatment for moving the teeth of the patient closer toward or to the second positions. In some variants, the interproximal segments, which can include interproximal loops, can be increasingly stiffer with each successive archwire (e.g., the interproximal segments of the intermediate archwire can be stiffer than those of the initial archwire). In some variants, onearchwire is used in a treatment plan instead of multiple. In some variants, two, three, four, five, or more archwires can be used for each arch (e.g., upper and lower arches) in a treatment plan. In some variants, an archwire can be installed to move the teeth toward a configuration other than a final planned alignment to accomplish a treatment goal, which can include moving teeth from a crowded arrangement to provide space for tooth rotation and / or bracket bonding. Malocclusion of the teeth can be treated using one or more arch wires to move the patient’s teeth using nonsliding and / or sliding mechanics.

[0075] FIG. 1A illustrates an example variant of an archwire 100, which can also be referred to as an archform. The illustrated variant of the archwire 100 along with other embodiments of the archwire are described in U.S. Patent Application No. 17 / 303,860, filed June 9, 2021, now issued as U.S. Pat. No. 12,090,025, the entirety of which is hereby incorporated by reference herein. As will be described in detail below, the present disclosure includes aspects of a system for and method of shaping archwires such as the archwire 100 described herein, archwires described in U.S. Patent No. 9,427,291, and / or archwires described in U.S. Pat. No. 12,090,025. However, while the systems for and methods of shaping an archwire are particularly useful in forming the described archwire 100 it should be appreciated that aspects of the system for and method of shaping an archwire described herein can have utility in forming other types of orthodontic archwires including archwires that utilize sliding mechanics and / or positioned buccally rather than lingually. The archwire 100 can have a polygonal (e.g., rectangular, square), circular, oval, irregular, and / or other shaped cross-section. The archwire 100, as described herein, can be cut (e.g., laser, wateijet, punching, etc.) from a sheet of material, such as shape memory material, which can include shape memory alloys (e.g., nickel titanium such as Nitinol) and / or shape memory polymers. The archwire 100, as illustrated in FIG. 1A, can have a planar (e.g., flat) shape. The archwire 100 can correspond to a segment of an upper or lower dental arch of a patient. The archwire 100 can correspond to an entirety of an upper or lower dental arch of a patient.

[0076] The archwire 100 can include a plurality of connectors or connector portions 102 (e.g., bracket connectors, anchors) that can be coupled to orthodontic brackets to install the archwire 100 in the mouth of a patient and / or be directly bonded to a patient’s teeth without an orthodontic bracket. The archwire 100 can include a plurality of interproximal segments 104 (e.g., segments). The interproximal segments 104 can be disposed between adjacent connectors 102. The interproximal segments 104 can correspond to interdental spaces between adjacent teeth ofthe patient. The interproximal segment 104 can include one or more loops. The loops can extend in a gingival direction when the archwire 100 is installed in the mouth, which can improve aesthetics and / or facilitate flossing. The loops can open to move adjacent teeth apart from each other. The loops can close to move adjacent teeth closer together. The loops can be various shapes, including U, T, tear-drop, triangular, rectangular, boot, and / or others. The loops of the archwire 100 can have varying rigidity. For example, the forces to move molars can be greater than other teeth; accordingly, the loops adjacent the molars can be more rigid than loops not adjacent molars. The rigidity can vary due to the curvature of the loop, shape of the loop, size of the loop, and / or width (e.g.. dimension 106 in the occlusal-gingival direction). In some variants, the loops of the intermediate archwire can be more rigid than corresponding loops of the initial archwire, and the loops of the final archwire can be more rigid than the corresponding loops of the intermediate archwire. The loops can extend (e.g., curve) gingivally down from one connector 102 to an intermediate gingival position and back up occlusally to another adjacent connector 102 such that the loop is open in an occlusal direction, which can be beneficial for flossing.

[0077] FIG. IB illustrates the connector 102 (e.g., bracket connector, anchor, male fastener) of an archwire 100. The connector 102 can be coupled to an orthodontic bracket such that the connector 102 does not slide with respect to the orthodontic bracket. In some variants, the connector 102 can be directly coupled (e.g., bonded, adhered) to the tooth of a patient. The connector 102 can be oriented in different orientations to move a tooth of a patient. The connector 102 can be disposed between interproximal segments 104. The interproximal segments 104, as described herein, can apply forces to adjacent connector(s) 102 to move teeth of a patient.

[0078] The connector 102 can have arms 108. The arms 108 can extend in a direction that is opposite that of a tab 110 (e.g., tongue) of the connector 102. The arms 108 can extend in at least an occlusal or gingival direction. The arms 108 can grip one or more features of an orthodontic bracket to help secure the connector 102 and / or provide improved control of a tooth of the patient. The arms 108 can grip a retainer of the orthodontic bracket. For example, the arms 108 can grip, hold, grasp, hug, snap around, and / or otherwise interface with the mesial and distal sides of the retainer or other portion of the orthodontic bracket. In some variants, the arms 108 can hold the archwire 100 (e.g., connector 102) in place on the bracket as an operator positions a tool to secure the connector 102 to the bracket. The arms 108 can include outer sides that are curved, which can help the arms 108 to better grip the retainer of the bracket.

[0079] A recess 116, also referred to as a gap, can be disposed between the arms 108. The recess 116 can receive a C spring of the orthodontic bracket and / or other feature when the connector 102 is locked into a slot of the orthodontic bracket. The periphery defining at least a portion of the recess 116 can contact the C spring. The C spring can apply a force against the periphery of the recess 116 to push the connector 102 against stops of the bracket which can position a portion of the connector 102 under overhangs of the stops. The connector 102 can include contact surfaces 114 which can contact the stops of the orthodontic bracket. The contact surfaces 114 can be flat to provide a secure point of contact with the stops of the orthodontic bracket. The stops of the orthodontic bracket can have corresponding flat surfaces. The contact surfaces 114 can be disposed on a side of the connector 102 that is opposite the arms 108 and / or recess 116. The contact surfaces 114 can be disposed on opposing sides of the tab 110.

[0080] The tab 110 can be disposed on a side of the connector 102 that is opposite the arms 108 and / orrecess 116. The tab 110 can be disposed in a gap between stops of the orthodontic bracket when the connector 102 is disposed in the slot of the orthodontic bracket. The tab 110 can contact inner sides of the stops, which can help to prevent sliding of the connector 102 in a mesial- distal direction relative to the orthodontic bracket. The tab 110 can extend in a gingival or occlusal direction. The tab 110 can include a groove 112. The groove 112 can be disposed on an end of the tab 110. The groove 112 can receive a tool to facilitate positioning the connector 102 into the slot of the orthodontic bracket or removing the connector 102 therefrom. The groove 112 can help to prevent inadvertent sliding of the tool being used to place the connector 102 into the slot of the orthodontic bracket. The connector 102 can include curves to reduce stress concentrators.

[0081] FIG. 1C illustrates the archwire 100 in a custom non-planar shape (e.g., custom 3D shape, custom memorized shape, custom memorized 3D shape). The custom non-planar shape corresponds to a planned alignment of a patient’s teeth. As described herein, the archwire 100 can correspond to a segment or the entirety of a patient’s upper or lower dental arch. As illustrated in FIG. 1C, the archwire 100 has an arch shape.

[0082] FIG. 2 illustrates an orthodontic bracket 200. The bracket 200 can be disposed on the lingual or buccal side of a patient's teeth. The bracket 200 can couple with the connector 102 of the archwire 100 to facilitate moving a patient's teeth using non-sliding mechanics. In some variants, sliding and / or non-sliding mechanics can be used. In some variants, the bracket 200 can have utility when used with archwires of different configurations than those described herein. The bracket 200 can include a slot 208, also referred to as a receiving region or receivingspace, that can receive the connector 102 of the archwire 100 therein such that the connector 102 is prevented from sliding relative to the bracket 200 when installed in a patient's mouth. The slot 208 can be positioned between a retainer 202 and stops 204, 205. The slot 208 can be at least partially defined between the retainer 202, stops 204, 205, and a face 224 of the bracket 200.

[0083] As described herein, the retainer 202 can help to retain the connector 102 within the slot 208. The retainer 202 can at least be positioned proximate or at a gingival or occlusal side of the bracket 200. The retainer 202 can extend from the face 224 of the bracket 200. The retainer 202 can include one or more features to improve handling the bracket 200. For example, the retainer 202 can have a protuberance 210, also referred to as a bump, protrusion, or engagement region, that can be gripped by a tool during handling of the bracket 200. The protuberance 210 can extend in a gingival or occlusal direction.

[0084] The retainer 202 can include one or more features to improve retention of the connector 102 received in the slot 208 of the bracket 200. For example, the retainer 202 can include an overhang 206, e.g., extension. The overhang 206 can help hold the connector 102 within the slot 208. The overhang 206 can be offset from the face 224. The overhang 206 can extend over the slot 208 and / or face 224. The overhang 206 can include a curved portion 214 that extends over the slot 208 and / or face 224 of the bracket 200. The retainer 202 and / or overhang 206 can include an angled surface 218 that can facilitate the connector 102 being positioned within the slot 208 of the bracket 200 at an angle before being rotated toward the face 224 of the bracket 200 and being locked within the bracket 200, such as in the slot 208. The retainer 202 can include a recess 220, also referred to as a gap, undercut, cutout, space, etc., that can facilitate the connector 102 being rotated in and out of the slot 208 of the bracket 200 as detailed herein.

[0085] The bracket 200 can include a spring 216 (e.g., lock spring) that can facilitate locking the connector 102 of the archwire 100 within the bracket 200. The spring 216 can be a compressible material with resilient properties that can be biased to a certain position. The spring 216 can be a C spring, rounded spring, leaf spring, etc. The spring 216 can be housed within an opening 212. The opening 212 can be disposed through at least a portion of the retainer 202. The C spring 216 can be inserted into the opening 212 by way of a face of the bracket 200 that is opposite the face 224. The C spring 216 can be exposed to the slot 208 such that the connector 102 can contact the C spring 216 when positioned within the slot 208. The C spring 216 can be oriented with a longitudinal axis thereof oriented perpendicularly relative to the plane of the face 224. The opening 212 can be contoured and / or shaped to prevent titling and / or rattling of the Cspring 216 within the opening 212. The opening 212 can be bounded by a periphery that can help to prevent the C spring 216 from deflecting beyond a desired range (e.g., beyond elastic deformation). With the connector 102 of the archwire 100 in the bracket 200, the C spring 216 can apply a force to the connector 102 that pushes the connector 102 against and / or at least partially under the stops 204, 205 such that the connector 102 is locked within the slot 208 of the bracket 200.

[0086] The stops 204, 205 can be proximate an opposite end of the bracket 200 relative to the retainer 202. In some variants, the stops 204, 205 can be in a mirrored configuration about a central plane of the bracket 200. The stops 204, 205 can include receiving spaces 228, 229, respectively. The receiving spaces 228, 229 can be at least partially bounded by extensions (e g., overhangs) of the stops 204, 205. The receiving spaces 228, 229, which can also be referred to as pockets or cutouts, can receive, respectively, a portion of the connector 102 therein to secure the connector 102 within the slot 208. In some variants, the bracket 200 can include two stops 204, 205. In some variants, the bracket 200 can include one, three, or four or more stops that can help retain the connector 102 of the archwire 100 within the bracket 200. The stops 204, 205 can be spaced apart from each other, which can be in the mesial-distal direction. A gap 234 can separate the stops 204, 205. The gap 234 can receive the tab 110 of the connector 102, as described herein. The portion of the face 224 spanning the gap 234 can be at least flat, angled, or curved. The portion of the face 224 spanning the gap 234 can be angled relative to other portions of the face 224 and / or curved at an end of the bracket 200.

[0087] The bracket 200 can include ramps 232, 233. The ramps 232, 233 can also be referred to as inclined surfaces, protrusions, angled surfaces, wedges, bumps, etc. The ramps 232, 233 can extend away from the face 224 of the bracket 200. The ramps 232, 233 can push the connector 102 against the stops 204, 205 to help secure the connector 102 within the slot 208. The ramps 232, 233 can push the connector 102 against the overhangs of the stops 204, 205. The ramps 232, 233 can include a flat surface that can engage the connector 102 when the connector 102 is secured within the slot 208. In some variants, the ramps 232, 233 can extend beyond a width of the stops 204, 205, respectively, which can help improve rotational control of a tooth.

[0088] The bracket 200 can include a protrusion 226 (e.g., bump). The protrusion 226 can extend from the face 224. The protrusion 226 can apply a force against the connector 102, when positioned within the slot 208, to push the connector 102 against the stops 204, 205 and / or overhang 206 of the retainer 202 to help secure the connector 102. The protrusion 226 can extendlaterally beyond a width of the retainer 202, which can help improve rotational control of a tooth. The protrusion 226 can extend laterally beyond the stops 204, 205. In some variants, the opening 212 can disrupt a portion of the protrusion 226.

[0089] The bracket 200 can include inclined surfaces 222, 223 that can facilitate inserting a connector 102 within the slot 208 of the bracket 200 before rotating the connector 102 toward the face 224 of the bracket 200 to lock the connector 102 into place. The inclined surfaces 222, 223 can be positioned on opposing sides of the retainer 202.

[0090] The bracket 200 can include lateral extensions 236, 237, which can also be referred to as lateral wings. The lateral extensions 236, 237 can help the bracket 200 to better control movement of a molar or other tooth. For example, the lateral extensions 236, 237 can facilitate better rotational control. The lateral extensions 236, 237 can also provide more surface area for a textured surface 230 for improved bonding.

[0091] The bracket 200 can include a textured surface 230, also referred to as a surface with undercuts, cuts, gaps, voids, and / or slots. The textured surface 230 can be disposed on a side of the bracket 200 that is opposite the face 224. The textured surface 230 can facilitate bonding the bracket 200 to a surface of the patient's teeth. Specifically, an adhesive applied to the textured surface 230 can bond the textured surface 230 to the surface of the patient's tooth. The textured surface 230 can provide an increased surface area to facilitate improved bonding compared to an un-textured surface.

[0092] FIG. 3 illustrates the connector 102 coupled to the bracket 200. As illustrated, the connector 102 is disposed in the slot 208 of the bracket 200. The C spring 216 can push the connector 102 against the stops 204, 205 and / or under at least a portion of the stops 204, 205. The contact surfaces 114 can contact the stops 204, 205. The force applied by the C spring 216 can lock the connector 102 under the overhangs of the stops 204, 205 and the overhang 206 of the retainer 202.

[0093] The bracket 200 and / or connector 102 of the archwire 100 can include modifications to accommodate the various teeth of the patient, such as the molars, bicuspids, lower anterior, and upper central teeth.

[0094] FIG. 4A illustrates an archwire 1000 (e.g., archwire). The archwire 1000 can have varying cross-sections, which can at least include circular, oval, polygonal (square, rectangular, etc.), irregular, and / or others. The archwire 1000 can be formed with a wire bender. The archwire 1000, as illustrated, is custom shaped to correspond to a planned alignment of apatient’s teeth. The archwire 1000 can correspond to a segment of a patient’s dental arch or the entirety of the patient’s dental arch. The archwire 1000 can include connectors 102 that can be coupled to orthodontic brackets such that the connectors 102 do not slide with respect to the orthodontic brackets. The connectors 102 can be loops (e.g., male loops) that extend occlusally or gingivally relative to a longitudinal axis of the archwire 1000. The loops can be various shapes, including U, T, tear-drop, triangular, rectangular, boot, and / or others.|0095J The archwire 1000 can include interproximal segments 104, which can include loops. The interproximal segments 104 can be disposed between adjacent connectors 102. The interproximal segments 104 can extend gingivally relative to a longitudinal axis of the archwire 1000, which can facilitate flossing and / or hide the loops from view. When the archwire 1000 is installed in a patient’s mouth, the interproximal segments 104 can exert forces on the teeth of the patient to move the patient’s teeth using non-sliding mechanics. In some variants, the interproximal segments 104 can include loops that extend in the gingival and / or occlusal direction. The connectors 102 and loops of the interproximal segments 104 can extend in opposite directions (e.g., one in the occlusal direction and the other in the gingival direction), the same directions, or a mix of the opposite and same.

[0096] FIG. 4B illustrates an archwire 1000’ similar to the archwire 1000 but with the connectors 102 extending in the same direction as the loops of the interproximal segments 104 (e.g., gingivally relative to the longitudinal axis of the archwire 100). The archwires 1000, 1000’ can be custom shaped and heat treated as described herein.

[0097] FIGS. 5A and 5B illustrate a shaping system 300 that can custom shape an archwire, which can at least include the archwires described herein. The shaping system 300 can include a robot 306 (e.g., machine, automated machine). The robot 306 can perform automated movements (e.g., tasks), which can increase accuracy and / or repeatability of the various processes described herein. The robot 306 can include servos, actuators, motors, and / or other mechanisms to perform movements. The robot 306 can include joints (e.g., ball, hinge, pin, screw, prismatic, knuckle, turnbuckle, bolt, cotterpin, universal, etc.) to facilitate movements. The robot 306 can include one or more sensors, which can include optical, proximity, position, pressure, force, temperature, etc. In some variants, the robot 306 can be fully automated (e.g., no manual movement of the robot 306 is permitted when active). In some variants, the robot 306 can be moved manually by an operator to perform a movement. In some variants, some of the steps of a process can be performed by way of manual manipulation of the robot 306 by an operatorand other steps of the process can be performed by way of automated movement by the robot306.

[0098] The shaping system 300 can include a fixture 328 (e.g., support, block, working surface). An archwire 100 can be disposed on the fixture 328, which can include being positioned in a channel 330 (e.g., groove, track, lane) of the fixture 328. The fixture 328 can support the portion of the archwire 100 not being shaped and / or heat set while another portion of the archwire 100 is being shaped and / or heat set. The archwire 100 can be translated within the channel 330. The archwire 100 can at least be any of the archwires described herein.

[0099] The robot 306 can be disposed on a surface 302 (e.g., platform) with a plurality of holes 304. The fixture 328 can be disposed on the surface 302. The plurality of holes 304 can be in a grid pattern or other type of fixed pattern. The plurality of holes 304 can facilitate coupling the robot 306 and / or fixture 328 to the surface 302 such that the robot 306 and fixture 328 are fixed in place relative to each other. In some variants, the robot 306 can be disposed above the surface 302 upon which the fixture 328 is mounted. In some variants, the shaping system 300 can include a plurality of robots 306, which can at least include two, three, four, or more robots 306. In some variants, one or more robots 306 can be positioned above the fixture 328 and / or the surface 302 upon which the fixture 328 is mounted and / or one or more robots 306 can be positioned on the surface 302. In some variants, one or more robots 306 can be disposed on a surface that is transverse relative to the surface 302.

[0100] The robot 306, as described herein, can move the portions of the archwire 100 to custom shape the archwire 100. The robot 306 can include a base 308. The base 308 can be coupled to the surface 302 such that the base 308 does not move relative to the surface 302. The robot 306 can include sensor(s), actuator(s), motor(s), arm(s), controller(s), processor(s), memory device(s), communication interface(s) (e.g., wireless and / or wired data interface(s)), and / or other hardware to perform the actions (e.g., processes, methods, steps) performed herein.

[0101] The robot 306 can include one or more mounts and / or members rotatably coupled together to facilitate movement, which can at least include a first mount 310, first member 312, second member 314, second mount 316, third member 318, fourth member 320, and / or tool 322. The first mount 310 can be rotatably mounted to the base 308. The first mount 310 can rotate about a longitudinal axis of the base 308. The first member 312 can be rotatably coupled to the first mount 310. The second member 314 can be rotatably coupled to the first member 312. The second mount 316 can be rotatably coupled to the second member 314. The second mount316 can rotate about a longitudinal axis of the second member 314. The third member 318 can be rotatably coupled to the second mount 316. The fourth member 320 can be rotatably coupled to the third member 318. The fourth member 320 can rotate about a longitudinal axis of the third member 318.

[0102] The fourth member 320 can include a tool 322, which can also be referred to as holder, gripper, fastener, clamp, vise, and / or clasp. The tool 322 can grasp (e.g., hold) a connector 102 of the archwire 100 to position the connector 102 in a position that corresponds to a digital marker, digital bracket, and / or tooth in the digital model with the teeth in the planned alignment.

[0103] The system 300 can include a holder 324 (e.g., fastener, vise, clasp, clamp). The holder 324 can hold (e.g., retain, secure) a connector 102 adjacent the connector 102 held by the tool 322 as the tool 322 moves a connector 102 to custom shape the archwire 100. The holder 324 can be coupled to, which can include being integrally formed with, the fixture 328. The holder 324 can automatically close and / or open to secure and / or release a connector 102 of an archwire 100.

[0104] The system 300 can include a heating device 334, which can be a heat gun, electrode, and / or other suitable device, to set (e.g., heat set) the archwire 100 in a custom nonplanar shape. The heating device 334, in some variants, can be disposed below the holder 324. In some variants, the heating device 334 can be coupled to the surface 302. In some variants, the heating device 334 can be coupled to the robot 306, which can at least include the fourth member 320 and / or tool 322. The heating device 334 can be automatically activated and / or deactivated by the system 300 to heat set the archwire 100. When the heating device 334 includes an electrical current system (e.g., electrode), the electrode can contact the archwire 100 and apply an electrical current thereto, which can raise the local temperature of the archwire 100 to heat set the local portion of the archwire in the custom nonplanar shape.

[0105] The system 300 can include an actuator 332, which can also be referred to as linear actuator, feeder, advancer, wheel, and / or gear. The actuator 332 can advance or retract the archwire 100, which can include advancing the archwire 100 such that the holder 324 can grasp a connector 102 and / or the tool 322 of the robot 306 can grasp another adjacent connector 102 for custom shaping. In some variants, the system 300 does not include a separate actuator 332 and the robot 306 can move the archwire 100 to position a connector 102 at the holder 324. Theactuator 332 can automatically advance and / or retract the archwire 100 to position connectors 102 for grasping by the holder 324 and / or tool 322.

[0106] In some variants, the system 300 can include one or more moveable holders 336 (e.g., fasteners, vises, clasps, clamps). The system 300 can include the one or more moveable holders 336 in combination with the actuator 332 or in place of the actuator 332. The one or more moveable holders 336 can hold (e.g., grasp, clamp, retain) one or more of the connectors 102 of the archwire 100 and be actuated (e.g., translated) to advance or retract the archwire 100, which can include advancing the archwire 100 such that the holder 324 can grasp a connector 102 and / or the tool 322 of the robot 306 can grasp a connector 102 for custom shaping. The one or more moveable holders 336 can automatically close and / or open to secure and / or release one or more connectors 102 of an archwire 100.

[0107] FIG. 6 illustrates a schematic of a system 500 that can include a scanning device 408, design system 400, shaping system 300, and / or clinician system 406. The systems, devices, and / or features of the system 500 can communicate via wireless and / or wired communication.

[0108] The scanning device 408 can be used to perform a scan (e.g., 3D scan(s) and / or 2D scan(s)) of the inside of the patient’s mouth (e.g., dental arches). The scan can capture data regarding the type, size, shape, contours, surface features, positioning, and / or other characteristics of the patient’ s teeth, gums, and / or bone structure. The scans can be taken by the patient, caretaker of the patient, and / or clinician. The scan can be performed using a camera and / or sensor of a computer, device connected to a computer, and / or a mobile device, such as a smartphone. In some variants, an application can be used to perform the scans — providing the patient with instructions on how to perform the scan and when a scan is successful. The scan can be performed using the mobile device’s built-in camera or via an attachment that operatively connects to the mobile device or computer. The scan data can be sent to a design system 400.

[0109] The design system 400, which can include a user interface 402 and / or display 404, can create and / or be used to create a virtual digital model of the patient’s teeth in first positions (e.g., maloccluded positions) based on the scan data. The digital model can represent the unique size, shape, contours, surface features, positioning, orientation, and / or other characteristics of the patient’s teeth, gums, and / or bone structure. The digital model can be displayed to an operator via a display 404 and / or user interface 402 of the design system 400 for viewing and / or manipulation. The design system 400 can segment and / or be used to segment thedigital teeth of the digital model to enable movement of the digital teeth of the digital model. The operator can move the digital teeth of the virtual model to second positions (e.g., an alignment, planned alignment, final alignment). The operator can select, modify, design, and / or place digital brackets on the digital teeth of the virtual model. In some variants, the operator can select, modify, design, and / or couple one or more digital archwires to the digital brackets. In some variants, the operator can determine and / or select, modify, and / or design a number of archwires to be used during treatment (e.g., one, two, three, four, or more). In some variants, the operator can determine, select, and / or design a rigidity for the archwire(s), which can include increasing a rigidity of the archwire(s) in a sequence of implementation. In some variants, the operator can design and / or modify the digital archwire(s) based on the qualities of a patient’s teeth (e g., accommodate for a missing tooth by omitting one or more connectors and / or interproximal loops). In some variants, the operator can move the digital teeth with the digital brackets disposed thereon from the second positions back to first positions, which can ensure that the digital teeth and / or digital brackets do not interfere with each other during movement. In some variants, the operator can place digital brackets on the digital teeth with the digital teeth in the first positions prior to moving the teeth to the second positions, which can ensure that the digital teeth and / or digital brackets do not interfere with each other during movement. In some variants, the operator can place digital markers on and / or in the digital brackets (e.g., in the slots of the digital brackets) to virtually plan the positioning of the connectors of the archwire. In some variants, the operator can place digital markers on and / or proximate the digital teeth to virtually plan the positioning of the connectors of the archwire. In some variants, a software program can automatically place digital markers on and / or in the digital brackets (e.g., in the slots of the digital brackets). In some variants, a software program can automatically place digital markers on and / or proximate the digital teeth. In some variants, a software program can initially place the digital markers and the operator can then alter the positioning. In some variants, the operator can select, modify, design, and / or couple a digital archwire directly to the digital teeth of the digital model. In some variants, a software program can automatically move the digital teeth of the virtual model to second positions; select, modify, design, and / or place digital brackets on the digital teeth of the virtual model; select, modify, design, and / or couple an archwire to the digital brackets; determine, select, and / or design a rigidity for the archwire(s); design and / or modify the digital archwire(s) based on the qualities of a patient’s teeth; move the digital teeth with the digital brackets disposed thereon from the second positions back to first positions; place digital markers on and / or in the digitalbrackets and / or on and / or proximate the digital teeth; and / or select, modify, design, and / or couple a digital archwire directly to the digital teeth of the digital model. In some variants, user preference data corresponding to a patient can be received by the design system 400 and considered by the operator and / or software program.

[0110] Treatment data, which can include scan data and / or data manipulated, associated, and / or created by the design system 400, can be communicated to a clinician system 406. The treatment data can at least include data relating to the virtual model with virtual teeth in the first positions; the virtual model with teeth in the second positions; a movement path of the teeth from the first to second positions; selection, modification, design, and / or placement of digital brackets; placement of digital markers; selection, modification, design, and / or coupling of archwire(s); rigidity and / or modification of archwire(s); patient preference(s); and / or other data. The clinician system 406 can be accessed by a clinician to review the treatment data. The clinician can advise as to alterations to the treatment plan and / or data; these advisements can be communicated to the design system 400 for consideration by the operator. For example, the clinician can review a virtual model of the teeth in the second positions (e.g., alignment) and indicate changes, which are communicated to the design system 400 and / or by way of other communication channels to the operator of the design system 400. In some variants, a patient can review treatment data, which can include a virtual model of the teeth in the second positions, and request alterations; these requested alterations can be considered by the operator and / or clinician.[OHl] Treatment data can be communicated to the shaping system 300. The shaping system 300 can include the robot 306, fixture 328, actuator 332, one or more moveable holders 336, holder 324, and / or heating device 334, as described herein. The tool 322 of the robot 306 can grasp a first connector 102 of the archwire 100 while the holder 324 grasps an adjacent second connector 102 of the archwire 100. The robot 306 can move the first connector 102 to a position relative to the adjacent second connector 102 held by the holder 324 that corresponds to that of a corresponding digital marker (e.g., coordinates) in the digital model, which can place the interproximal segment 104 between the first and second connectors 102 in a custom nonplanar shape that is configured to move the patient’s teeth toward the digitally planned alignment. The heating device 334 can then heat set the interproximal segment 104 between the first and second connectors 102 by applying heat by way of the heating device 334 such that the custom nonplanar shape is the default shape (e.g., memorized shape) of the interproximal segment 104 and / or first and second connectors 334. The tool 322 can release the first connector 102 and the holder 324can release the second connector 102. The actuator 332 and / or one or more moveable holders 336 can advance the archwire 100 (e.g., advance the archwire 100 through the channel 330 of the fixture 328) to position the second connector 102 for grasping by the tool 322 and an adjacent third connector 102 for grasping by the holder 324.

[0112] The tool 322 of the robot 306 can grasp the second connector 102 of the archwire 100 and the holder 324 can grasp the third connector 102 of the archwire 100. The robot 306 can move the second connector 102 to a position relative to the third connector 102 held by the holder 324 that corresponds to that of a corresponding digital marker in the digital model, which can place the interproximal segment 104 between the second and third connectors 102 in a custom nonplanar shape that is configured to move the patient’s teeth toward a digitally planned alignment. The heating device 334 can then heat set the interproximal segment 104 between the second and third connectors 102 by applying heat by way of the heating device 334 such that the custom nonplanar shape is the default shape (e.g., memorized shape) of the interproximal segment 104. The system 300 can proceed accordingly until the entirety of the archwire 100 (e.g., all of the interproximal segments 104) is heat set in the custom nonplanar shape corresponding to the planned alignment of the patient’s teeth. As described herein, in some variants, the archwire 100 can be heat set by electrical current.

[0113] FIG. 7 illustrates an example method 600 of creating treatment data (e.g., a treatment plan), which can include a virtual model, for a patient and communicating the treatment data to a shaping system. This flow diagram is provided for the purpose of facilitating description of aspects of some variants. The diagram does not attempt to illustrate all aspects of the disclosure and should not be considered limiting.

[0114] At block 602, the design system 400 can receive scan data of a patient’ s mouth from a scanning device 408. A scan (e.g., 3D scans and / or 2D scans) can be taken of the inside of the patient’s mouth (e.g., dental arches, gums, bone structure, etc.). The scan can capture data regarding the type, size, shape, contours, surface features, positioning, and / or other characteristics of the patient’s teeth. The scans can be taken by the patient, caretaker of the patient, and / or clinician. The scan can be performed using a camera and / or sensor of a computer, device connected to a computer, and / or a mobile device, such as a smartphone. In some variants, an application can be used to perform the scans — providing the patient and / or clinician with instructions on how to perform the scan and when a scan is successful. The scan can beperformed using the mobile device’s built-in camera or via an attachment that operatively connects to the mobile device or computer.

[0115] At block 604, a virtual model (e.g., digital model) of the patient’s teeth can be created by the design system 400 based on scans of the inside of the patient’s mouth. The virtual model can represent the unique size, shape, contours, surface features, positioning, and / or other characteristics of the patient’s teeth. In some variants, the virtual model can be automatically generated by software implemented on a computing device using the scans of the inside of the patient’s mouth. In some variants, the design system 400 can segment each digital tooth of the virtual model to enable movement of the digital teeth with respect to each other. The virtual model can digitally represent the patient’s teeth in first positions (e g., maloccluded positions).

[0116] At block 606, the digital teeth can be moved from the first positions to second positions (e.g., an alignment, planned alignment, final alignment, planned configuration). The digital teeth can be moved by an operator utilizing the design system 400 and / or a software program. In some variants, the operator and / or software program can consider patient and / or clinician input when moving the digital teeth to the second positions. In some variants, the operator can modify the second positions of the digital teeth as planned by the software program.

[0117] At block 608, digital brackets suitable for bonding on surfaces of the digital teeth can be selected from a variety of digital brackets and placed on the surfaces of the digital teeth. An operator utilizing the design system 400 and / or a software program can select and / or place digital brackets on the digital teeth. The digital brackets can be placed on buccal or lingual surfaces of the digital teeth. Certain types and / or sizes of brackets can be more suitable and / or preferred for bonding on a given tooth but not others.

[0118] At block 609, digital markers can be placed on and / or in the digital brackets to indicate positions (e.g., orientation, placement, etc.) for the connectors 102 of the archwire 100. For example, the digital markers can be placed in the receiving spaces (e.g., slots) of the digital brackets to indicate the positions for the connectors 102 of the archwire 100. The digital markers can, in some variants, be sized and shaped the same as the connectors 102. In some variants, a digital archwire can be coupled to the digital brackets. In some variants, the archwire 100 can be directly bonded to a patient’s teeth without brackets 200. In some variants, the archwire 100 can be directly bonded to some of the patient’s teeth and coupled to brackets bonded to some of the patient’ s teeth. Accordingly, in some variants, the digital markers can be disposed on and / orproximate the digital teeth to allow for bonding directly to the teeth without the use of a bracket. An operator utilizing the design system 400 and / or a software program can place the digital markers as described herein. In some variants, a software program can automatically place the digital markers as described herein.

[0119] At block 610, treatment data can be communicated from the design system 400 to the clinician system 406. Treatment data, which can include scan data and / or data manipulated, associated, and / or created by the design system 400, can be communicated to a clinician system 406. The treatment data can at least include data relating to the virtual model with virtual teeth in the first positions; the virtual model with teeth in the second positions; a movement path of the teeth from the first to second positions; selection, modification, design, and / or placement of digital brackets; selection, modification, design, and / or coupling of archwire(s); rigidity and / or modification of archwire(s); patient preference(s), and / or other data; and placement (e.g., orientation, positioning, etc.) of digital markers. The clinician system 406 can be accessed by a clinician, such as an orthodontist, to review the treatment data. The clinician can advise as to alterations to the treatment plan and / or data. At block 612, this feedback (e.g., advisements) of the clinician can be communicated to and received by the design system 400 for consideration. For example, the clinician can advise as to alterations to the planned alignment. The clinician can advise as to bracket type and / or placement. The clinician can advise as to the size, shape, and / or stiffness of an archwire. The clinician can advise as to the number of archwires to use in a treatment plan.

[0120] At block 614, the treatment data can be modified based on the feedback from the clinician. In some variants, the operator and / or software program can modify the treatment data based on the feedback from the clinician.

[0121] At block 616, the treatment data or a portion thereof can be communicated (e.g., wirelessly and / or wired) to the shaping system 300 (e.g., robot 306). In some variants, data (e.g., coordinates) regarding the placement of the digital markers can be communicated to the shaping system 300 (e.g., robot 306).

[0122] In some variants, a clinician, such as an orthodontist, can communicate treatment plan data directly to the shaping system 300. In some variants, the clinician can alter a treatment plan and directly communicate the altered treatment plan to the shaping system 300. For example, in some variants, a clinician can review treatment plan data, which can include a virtual model of the patient’ s teeth in a planned alignment with one or more brackets and / or digitalmarkers positioned. The clinician can alter the position of one or more teeth, bracket selection, bracket placement, digital marker placement, archwire specifications, and / or other aspects of the treatment plan data and communicate the altered treatment plan to the shaping system 300 to shape the archwire. In some variants, a clinician can receive data for a virtual model of the patient’s teeth in the maloccluded positions, and the clinician and / or clinician system 406 can perform the steps described in reference to blocks 606-609 and communicate the treatment plan data to the shaping system 300. In some variants, scan data of a patient’s mouth can be received by the clinician system 406, which can include one or more computing devices, to create a virtual model of the patient’s teeth with teeth in maloccluded positions. The orthodontist and / or clinician system 406 can then perform one or more of the steps described in reference to blocks 606-609 and communicate the treatment plan data to the shaping system 300.

[0123] FIG. 8 illustrates an example method 700 of custom shaping an archwire based on treatment data. This flow diagram is provided for the purpose of facilitating description of aspects of some variants. The diagram does not attempt to illustrate all aspects of the disclosure and should not be considered limiting.

[0124] At block 702, the shaping system 300 (e.g., robot 306 and / or associated components such as a computer, etc.) can receive treatment data. For example, the shaping system 300 (e.g., robot 306) can receive treatment data regarding the positions (e.g., orientation, placement, etc.) of the digital markers (e.g., coordinates) in the virtual model with the digital teeth in the second positions. In some variants, the shaping system 300 (e.g., robot 306) can convert positions of the digital markers to a G-code to correlate the positions of the digital makers in 3D space. In some variants, the treatment data can include data regarding the virtual model with digital teeth in the second positions, selection and placement of digital brackets, positioning of digital markers, etc.

[0125] At block 704, the actuator 332 and / or one or more moveable holders 336 can advance an archwire 100 to position an nthconnector 102 to be accessible to the tool 322 of the robot 306. The actuator 332 and / or one or more moveable holders 336 can advance the archwire 100 to position an (n + l)thconnector 102 (e.g., next adjacent connector 102 relative to the nthconnector 102) to be accessible to the holder 324. The archwire 100 can be advanced through the channel 330 of the fixture 328. In some variants, the robot 306, in combination with or in place of the actuator 332 and / or one or more moveable holders 336, can advance the archwire 100 to a position for grasping by the holder 324 and / or robot 306.

[0126] At block 706, the robot 306 can actuate the tool 322 to hold (e.g., grasp, grip, clamp) the nthconnector 102. The holder 324 can acuate to hold (e g., grasp, grip, clamp) the (n + l)thconnector 102.

[0127] At block 708, the robot 306 can move the nthconnector 102 relative to the (n + l)thconnector 102 to a position based on the positions of a corresponding nthand / or (n + l)thdigital markers in the digital model, which can position the interproximal segment 104 between the nthconnector 102 and the (n + l)thconnector 102 in a custom nonpl anar shape that is configured to move the patient’s teeth to toward the digitally planned alignment of the digital model. The positioning, which can include orientation, of the nthconnector 102 can correspond to the positioning of an nthconnector digital marker. The positioning of the (n + l)thconnector 102 can correspond to the positioning of an (n + l)thconnector digital marker. The (n + l)thconnector 102 can be held in a fixed position by the holder 324 as the robot 306 moves the nthconnector 102. In some variants, the holder 324 can move the (n + l)thconnector 102 relative to the nthconnector 102 to a position based on the positions of corresponding nthand / or (n + l)thdigital markers in the digital model, which can position the interproximal segment 104 between the nthconnector 102 and the (n + l)thconnector 102 in a custom nonpl anar shape that is configured to move the patient’s teeth to toward the digitally planned alignment of the digital model.

[0128] At block 710, the heating device 334 can heat the interproximal segment 104 between the nthconnector 102 and the (n + 1 )thconnector 102 to heat set the interproximal segment 104 in the custom nonplanar shape such that the custom nonplanar shape is the default (e.g., memorized) shape of the interproximal segment 104. The heating device 334 can heat the archwire 100 (e.g., interproximal segment 104) to different temperatures (e.g., between 400 and 500 degrees Celsius, about 400 degrees Celsius, etc.) to heat set the archwire 100. As described herein, the heating device 334 can be a heat gun that applies heat to the interproximal segments 104. For example, the heat gun can be heated to 600 degrees Celsius to heat the archwire 100 to between 400 and 500 degrees Celsius. The heat gun can be a set distance away from the archwire 100 such that the impact of heat applied by the heat gun on the archwire 100 is known. The heat gun can apply heat to each interproximal segment 104 and / or adjacent connectors 102 of the archwire 100 for a period of time (e.g., about 20 seconds each). In some variants, the period of time can be lengthened or shortened depending on the thickness of the interproximal segments 104. For example, thicker interproximal segments 104 can be exposed to heat for longer periodsof time compared to thinner interproximal segments 104. Thinner interproximal segments 104 can be exposed to heat for shorter periods of time compared to thicker interproximal segments 104. In some variants, the heating device 334 can apply different heats to different archwires 100 and / or portions of archwires 100 depending on the geometry. In some variants, as described herein, the heating device 334 can include an electrode that applies an electrical current to the interproximal segment 104 to heat the interproximal segments 104. The electrode can apply a small amount of current (e.g., milliamps) to the interproximal segments 104 to raise the temperature of the interproximal segments 104 to a temperature (e.g., between 400 and 500 degrees Celsius). The electrode can apply the current for various amounts of time, which can include less than one second (e.g., millisecond range). The amount of current and / or the duration of the application of current can be adjusted, as described herein, based on the thickness of the interproximal segments 104 and / or other geometry of the archwire 100.

[0129] At block 712, it can be determined whether all interproximal segments 104 of the archwire 100 have been heat set in a custom nonplanar shape (i.e., whether the heat setting process is complete). For example, the shaping system 300 and / or system in communication with the shaping system 300 can determine whether all interproximal segments 104 of the archwire 100 have been heat set in a custom nonplanar shape. The shaping system 300 can determine that the heat setting of the archwire 100 is complete when a second to last connector 102 has been moved by the robot 306 to position the last interproximal segment 104 in a custom nonplanar shape for heat setting. The shaping system 300 can determine that heat setting of the archwire 100 is complete by comparing connectors 102 positioned by the robot 306 with corresponding digital markers, comparing connectors 102 held by the holder 324 with corresponding digital markers, comparing the interproximal segments 104 of the archwire 100 for which heat setting has been performed with digital interproximal segments 104 of a digital archwire 100 in the digital model, and / or other techniques. If all interproximal segments 104 of the archwire 100 have not been heat set in a custom nonplanar shape, the method 700 can return back to block 704 to then custom shape and then heat set the next adjacent interproximal segment 104.

[0130] If all interproximal segments 104 of the archwire 100 have been heat set in a custom nonplanar shape, the method 700 can proceed to block 714 and a notification can be generated to signal to an operator that the archwire 100 has been heat set in the custom nonplanar shape. The notification can be audible and / or visual. For example, the notification can be displayed on a display screen of the shaping system 300, design system 400, and / or a system (e.g.,device, portable electronic device) in communication with shaping system 300 and / or design system 400. The notification can be an audible notification emitted by a speaker of the shaping system 300, design system 400, and / or a system (e.g., portable electronic device) in communication with shaping system 300 and / or design system 400. In some variants, the notification can be generated after the archwire 100 has cooled to a temperature, which can be a temperature safe for human handling.|0131J At block 716, the holder 324 can release the (n + l)thconnector 102 and the robot 306, while holding the nthconnector 102, can move the archwire 100 to a storage space, such as a tray. In some variants, the archwire 100 can be moved to the storage space to cool. In some variants, the shaping system 300 can include a sensor to detect the temperature of the archwire 100, which can include generating a notification when a temperature of the archwire 100 reaches a threshold (e.g., temperature safe for handling by an operator). In some variants, the holder 324 can release the (n + l)thconnector 102 and the robot 306 can release the nthconnector 102 for retrieval. The shaping system 300 can then begin custom shaping and heat setting another archwire 100. In some variants, block 716 can precede block 714.

[0132] In some variants, the archwire 100 can be cut (e.g., laser, water jet) from a sheet of material on the fixture 328 or at a location accessible by the robot 306 for retrieval prior to custom shaping and / or heat setting. For example, the archwire 100 can be cut and then method 700 can commence, which can include the robot 306 retrieving the archwire 100 from a cutting area and delivering the archwire to the holder 324 to initiate custom shaping (e.g., method 700).

[0133] The archwire 100 can be heat treated to set a transformation temperature for the archwire 100. The transition temperature for the archwire between martensite and austenite phases can be set. The archwire can be in a martensite phase when the temperature of the archwire is below the transition temperature and in an austenite phase when the temperature of the archwire is above the transition temperature. The archwire can be heat treated such that the transition temperature for the archwire is between 75 and 97 degrees Fahrenheit. In some variants, the archwire can be heat treated such that the transition temperature for the archwire is between 80 and 90 degrees Fahrenheit. In some variants, the arch wire can be heat treated such that the transition temperature for the archwire is 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, or 98 degrees Fahrenheit or a temperature between any of the foregoing values. The archwire can be heat treated such that the archwire is in a martensite phase when the temperature of the archwire is between 65 and 75 degreesFahrenheit, which can typically correspond with room temperature. In some variants, the archwire can be heat treated such that the archwire is in a martensite phase when the temperature of the archwire is between 60 and 80 degrees Fahrenheit or any subrange or value therebetween. The archwire can be heat treated such that the archwire is in an austenite phase when the temperature of the archwire is between 97 and 99 degrees Fahrenheit, which can typically correspond with body temperature. In some variants, the archwire can be heat treated such that the archwire is in an austenite phase when the temperature of the archwire is between 90 and 100 degrees Fahrenheit or any subrange or value therebetween. In the martensite phase, the archwire can be flexible and / or pliable to facilitate easy installation. In the austenite phase, the archwire can be rigid and / or springy (e.g., activated) to exert forces on the patient’s teeth after installation. Accordingly, as a clinician handles and installs the archwire in a patient’s mouth, the archwire can be pliable to facilitate easy handling and installation. After installation, the archwire 100 can be heated by the patient’s mouth to or above the transition temperature such that the archwire is in the austenite phase and activated toward the custom nonplanar shape. In the austenite phase, the archwire can be rigid and / or springy to exert forces on the patient’s teeth to move the patient’s teeth. In the austenite phase, the archwire 100 can assume (e.g., attempt to assume) the custom nonplanar shape (e g., memorized shape, default shape), exerting forces on the patient’s teeth when coupled (e.g., coupled via brackets) to the patient’s teeth. The heat treating of the archwire can include heating the archwire in an oven and / or furnace. In some variants, the archwire 100 can be heat set in the custom nonplanar shape and the transition temperature set at the same time.

[0134] In some variants, the systems, processes, and methods described herein can be implemented using a computing system. For example, the shaping system 300 can be implemented using a computing system. The shaping system 300 can be in communication with one or more computing systems and / or data sources by way of one or more networks. The computing system can facilitate carrying out the functions, methods, acts, and / or processes described herein. The computing system can include a module that can be executed by a central processing unit.

[0135] FIGS. 9A and 9B illustrate a shaping system unit 800 that can custom shape an archwire into a custom nonplanar configuration, which can at least include the archwires described herein. The shaping system unit 800 can include one or more shaping system(s) 810, 812 for custom shaping an archwire, which can include one, two, three, four, or more shapingsystems. The features of the shaping systems 810, 812 can be incorporated with the features of the shaping system 300. The features of the shaping system 300 can be incorporated with the features of the shaping systems 810, 812. The shaping systems 810, 812 can, in some variants, custom shape archwires simultaneously, which can include custom shaping different archwires for the same patient (e.g., initial and intermediate archwires, archwires for the lower arch and upper arch, etc.) or different patients at the same time. For example, the shaping system 810 can custom shape an archwire for the upper arch of a patient while the shaping system 812 can custom shape an archwire for the lower arch of the patient.

[0136] The one or more shaping system(s) 810, 812 can be housed within an interior compartment of a housing 802. The housing 802 can include one or more doors to allow access into the interior of the housing 802 and the one or more shaping system(s) 810, 812. The doors can be opened to permit a user to access the one or more shaping system(s) 810, 812, for example, when loading or unloading one or more archwires into or out of the shaping system(s) 810, 812. The doors can be closed, which can include being locked, to isolate the shaping system(s) 810, 812 from the outside environment, for example, when the shaping system(s) 810, 812 are in operation shaping an archwire into a custom 3D shape. In some variants, the one or more shaping systems 810, 812 can pause operation automatically when one of the doors is opened. In some variants, the housing 802 can provide a controlled environment for the one or more shaping system(s) 810, 812. In some variants, the housing 802 can protect an operator from the components of the one or more shaping system(s) 810, 812 in operation. In some variants, the housing 802 can include one or more windows to enable an operator to view the interior with the doors closed. In some variants, the housing 802 can include transparent walls and / or panels to permit visibility inside. In some variants, the housing 802 can include one or more lights to illuminate the interior. In some variants, the housing 802 can include one or more secondary compartment(s) for containing shaping system unit 800 components that a user does not need to access as readily, for example, wiring or backup parts. The housing 802 can include vent(s) 804 to increase airflow into and / or out of the housing 802, which can include increasing airflow to cool the interior. In some variants, the vent(s) 804 can include fans for selectively increasing or decreasing airflow into and / or out of the housing 802.

[0137] In some variants, the shaping system unit 800 can include a user interface 806(e.g., screen, touch screen, display panel) that can provide users with information about and / or control of the shaping system(s) 810, 812. The user interface 806 can advantageously provideusers with information about the shaping system unit 800 and / or shaping system(s) 810, 812. In some variants, the user interface 806 can provide information such as temperature(s) inside the shaping system unit 800, progress of the shaping system(s) 810, 812 in shaping one or more archwires, and / or errors. In some variants, the user interface 806 can display warnings or error messages if the shaping system(s) 810, 812 encounter a problem during the shaping process and / or if the internal temperature of the custom shaping unit 800 and / or archwire surpasses a predetermined threshold. In some variants, the user interface 806 can allow a user to control or influence the operation of the shaping system unit 800 such as unlocking, locking, opening, and / or closing the housing 802 doors, opening or closing the vent(s) 804, and / or controlling the speed of fans in the vent(s) 804. In some variants, the user interface 806 can allow a user to control or influence operation of the shaping system(s) 810, 812. For example, in some variants, a user can start or stop operation of the shaping system(s) 810, 812 and / or input data relating to the configuration of digital markers in the digital model to influence operation of the shaping system(s) 810, 812. In some variants, the user interface 806 can enable a user to indicate the archwire (e.g., initial, intermediate, final, upper arch, lower arch, etc.) of a patient that is to be custom shaped by the one of the shaping system(s) 810, 812, which can prompt the retrieval of the data (e.g., instructions) for one of the shaping system(s) 810, 812 to correctly custom shape the archwire. In some variants, the shaping system unit 800 can include a scanner that can scan a computer readable code associated with the archwire (e.g., coupled to the archwire, on the archwire) to prompt the retrieval of the data (e.g., instructions) to correctly custom shape the archwire with one of the shaping system(s) 810, 812.

[0138] In some variants, the shaping system unit 800 can include controls 808 (e.g., buttons, switches, levers) that a user can interact with to operate the shaping system unit 800. For example, the controls 808 can lock, unlock, open, and / or close doors of the housing 802; control one or more lights, fans, vents, etc.; and / or start or stop operation of the shaping system(s) 810, 812. In some variants, the controls 808 can include an emergency off switch to stop operation of the shaping system(s) 810, 812.

[0139] In some variants, the shaping system unit 800 can include components (e.g., a cutting device) to cut (e.g., laser, waterjet, punching, etc.) the archwire 100 from a sheet of material, such as a shape memory material, which can include shape memory alloys (e.g., nickel titanium such as Nitinol) and / or shape memory polymers. In some variants, the shaping system 800 can automatically deliver the archwire 100 to the shaping system(s) 810, 812 to be customshaped after cutting the archwire 100 from a sheet of material, for example, through a conveyor, movable gripper, robot, and / or other mechanism.

[0140] FIGS. 10 and 11 illustrate a shaping system 810 that can custom shape an archwire 100, which can at least include the archwires described herein. The shaping system 810 and the shaping system 812 can include the same features and / or operate using the same processes as each other. The shaping system 810 can include a robot 874 (e.g., machine, automated machine). The robot 874 can perform automated movements (e.g., tasks), which can increase accuracy and / or repeatability of the various processes described herein. The robot 874 can include servos, actuators, motor, and / or other mechanisms to perform movements. The robot 874 can include joints (e.g., ball, hinge, pin, screw, prismatic, knuckle, turnbuckle, bolt, cotterpin, universal, etc.) to facilitate movements. The robot 874 can include one or more sensors, which can include optical, proximity, position, pressure, force, temperature, etc. In some variants, the robot 874 can be fully automated (e.g., no manual movement of the robot 874 is permitted when active). In some variants, the robot 874 can be moved manually by an operator to perform a movement. In some variants, some of the steps of a process can be performed by way of manual manipulation of the robot 874 by an operator and other steps of the process can be performed by way of automated movement by the robot 874.

[0141] The robot 874 can be disposed on a surface 894 (e.g., platform) with a plurality of holes 896. The plurality of holes 896 can be in a grid pattern or other type of fixed pattern. The plurality of holes 896 can facilitate coupling the robot 874 such that a base 876 of the robot 874 is fixed in place. The plurality of holes 896 can facilitate coupling the robot 874 to the surface 894 such that the relative positioning of the robot 874 is known. In some variants, the shaping system 810 can include a plurality of robots 874, which can at least include two, three, four, or more robots 874, which can be positioned on the surface 894 and / or other locations.

[0142] The robot 874, as described herein, can move portions of the archwire 100 to custom shape the archwire 100. The robot 874 can include a base 876. The base 876 can be coupled to the surface 894 such that the base 876 does not move relative to the surface 894. The robot 874 can include sensor(s), actuator(s), motor(s), arm(s), controller(s), processor(s), memory device(s), communication interface(s) (e.g., wireless and / or wired data interface(s)), and / or other hardware to perform the actions (e.g., processes, methods, steps) described herein.

[0143] The robot 874 can include one or more mounts and / or members rotatably coupled together to facilitate movement, which can at least include include a first member 878,first mount 880, second member 882, second mount 884, third member 886, fourth member 888, third mount 890, fifth member 892, and / or gripper 850. The first member 878 can be rotatably coupled to the base 876. The first member 878 can rotate about a longitudinal axis of the base 876. The first mount 880 can be rotatably coupled to the first member 878. The first mount 880 can pivot about an axis that is substantially perpendicular to the longitudinal axis of the first member 878. The second member 882 can be rotatably coupled to the first mount 880. The second mount 884 can be integral with the second member 882. The third member 886 can be rotatably coupled to the second mount 884. The fourth member 888 can be rotatably coupled to the third member 886. The fourth member 888 can rotate about a longitudinal axis of the third member 886. The third mount 890 can be rotatably coupled to the fourth member 888. The third mount 890 can pivot about an axis that is substantially perpendicular to the longitudinal axis of the fourth member 888. The fifth member 892 can be rotatably coupled to the third mount 890. The fifth member 892 can rotate about a longitudinal axis of the third mount 890.

[0144] The fifth member 892 can include a gripper 850 (e.g., holder, fastener, vise, clasp, clamp) that is described in further detail below. The gripper 850 can grasp (e.g., hold) the archwire 100. For example, the gripper 850 can grasp a connector 102 of the archwire 100 to position the connector 102 in a position that corresponds to a digital marker, digital bracket, and / or tooth in the digital model with the patient’s teeth in the planned alignment (see FIG. 11). The shaping system 810 can anchor portion(s) of the archwire 100 while the gripper 850 of the robot 874 grasps and / or repositions a connector 102 of the archwire 100 such that the connector 102 grasped by the gripper 850 can be moved relative to other portions of the archwire 100. For example, the shaping system 810 can anchor a connector 102 adjacent the connector 102 grasped by the gripper 850 such that, when the gripper 850 moves the connector 102, the shape of the interproximal segment (e.g., loops) 104 of the archwire 100 between the connector 102 grasped by the gripper 850 and the connector 102 anchored by the shaping system 810 can be custom shaped.

[0145] In some variants, the shaping system 810 can include a holder 814 (e.g., gripper, fastener, vise, clasp, clamp). The holder 814 can hold (e.g., receive, engage, grip, hold, support, retain, secure, grasp) a portion of the archwire 100 during an initiation process (e.g., startup process, loading process). A user can load a portion of the archwire 100 in the holder 814 such that the archwire 100 extends away from the holder 814 and the position and / or orientation of the archwire 100 is maintained by the holder 814. The holder 814 can be automatically and / ormanually actuated to grasp a portion of the archwire 100. In some variants, a portion of the archwire 100 can be automatically loaded into the holder 814. In some variants, the holder 814 can be coupled to the surface 894. In some variants, the holder 814 can be positioned above the surface 894. In some variants, the holder 814 can be positioned near an end of the shaping system 810. In some variants, the holder 814 can be stationary. In some variants, the holder 814 can be movable. In some variants, the holder 814 can be supported by a frame (e.g., stand, mount, fixture, etc.), which can include being disposed on (e.g., coupled to) the frame.

[0146] In some variants, the shaping system 810 can include a vision system 828, which can include a laser system. The vision system 828 can determine if the archwire 100 was correctly loaded into the holder 814, which can include verifying the position and / or orientation of the archwire 100. In some variants, the vision system 828 can automatically determine if the archwire 100 was correctly loaded into the holder 814. The vision system 828 can detect whether the archwire 100 is properly positioned and / or oriented after a portion of the archwire 100 has been loaded in the holder 814. In some variants, the vision system 828 can alert a user when a portion of the archwire 100 is not properly loaded in the holder 814, for example, through the user interface 806. A user can then reload a portion of the archwire 100 within the holder 814 to properly position and / or orient the archwire 100. In some variants, the vision system 828 can be coupled to the surface 894. In some variants, the vision system 828 can be positioned above the surface 894. In some variants, the vision system 828 can be movable. In some variants, the vision system 828 can be stationary.

[0147] The shaping system 810 can include a holder 832 (e.g., gripper, fastener, vise, clasp, clamp). The holder 832 can hold (e.g., receive, engage, grip, hold, support, retain, secure, grasp) a portion of the archwire 100 to support the archwire 100. The holder 832 can be automatically and / or manually actuated to grasp a portion of the archwire 100. In some variants, the holder 832 can automatically hold a portion of the archwire 100 after a user loads the archwire 100 into the holder 814. In some variants, the holder 814 and the holder 832 can both hold portions of the archwire 100 (see FIG. 10). In some variants, the holder 832 can be actuated to hold onto the portion of the archwire 100 when the vision system 828 determines that the archwire 100 was correctly received by the holder 814. In some variants, based upon the vision system 828 determining that the archwire 100 was correctly received by the holder 814 and / or the archwire data provided to the shaping system 810, the shaping system 810 can know the location in space of the features of the archwire 100. In some variants, the shaping system 810 can automaticallydetermine where the holder 832 should grasp a portion of the archwire 100, for example, using the archwire 100 position and / or orientation data acquired by the vision system 828. The shaping system 810 can move the holder 832 such that the holder 832 is positioned to hold a portion of the archwire 100 at the correct location. In some variants, the holder 832 can hold a portion of the archwire 100 at a location away from where the holder 814 is holding a portion of the archwire 100.

[0148] In some variants, the holder 832 can be coupled to the surface 894. In some variants, the holder 832 can be positioned above the surface 894. In some variants, the holder 832 can be positioned away from the holder 814. In some variants, the holder 832 can be movable. In some variants, the archwire 100 can move with the holder 832 after being grasped thereby. In some variants, the vision system 828 can move with the holder 832 and / or archwire 100 to determine (e.g., continuously determine) that the archwire 100 is properly held by the holder 832, which can include determining the position and / or orientation of the archwire 100. In some variants, the vision system 828 can move independently of the holder 832 and / or archwire 100, which can include moving to scan different portions of the archwire 100 to determine position and / or orientation of the archwire 100.

[0149] In some variants, the shaping system 810 can include an actuator 866 (e.g., linear actuator), a sled 838 (e.g., carriage), and / or a rail 864 (e.g., track). The actuator 866 can include a motor (e.g., an electric motor). The actuator 866 can move the holder 832, the vision system 828, and / or the sled 838. In some variants, the actuator 866 can move the holder 832 to grasp the archwire 100 at the correct location. In some variants, the actuator 866 can move the holder 832 after grasping a portion of the archwire 100 such that the archwire 100 moves with the holder 832, which can include removing the archwire 100 from the holder 814. In some variants, the actuator 866 can move the vision system 828 with the holder 832. In some variants, the actuator 866 can be coupled to the surface 894.

[0150] In some variants, the holder 832 and / or the vision system 828 can be disposed on (e.g., coupled to) the sled 838. The holder 832 and / or the vision system 828 can be positioned on an upper surface of the sled 838. The actuator 866 can move the sled 838 with the holder 832 and / or vision system 828 coupled thereto.

[0151] In some variants, the sled 838 can be movably mounted to a rail 864 such that the archwire 100, the holder 832, and / or the vision system 828 can move with the sled 838 as thesled 838 is moved on the rail 864. The sled 838 can be advanced or retracted along the rail 864 by the actuator 866. The sled 838 can be positioned above the rail 864 and / or the surface 894.

[0152] The rail 864 can be coupled to the surface 894. The rail can be positioned above the surface 894. The rail 864 can be linear. In some variants, the rail 864 can be non-linear or curved. The rail 864 can be positioned at an elevation lower than the holder 814, the holder 832, and / or the vision system 828. The rail 864 can be oriented such that it extends in substantially the same direction as the longitudinal axis of the archwire 100 when the holder 814 and / or the holder 832 hold portions of the archwire 100. Orienting the rail 864 in this manner can permit the sled 838 and / or holder 832 to move in a direction that is substantially the same as the longitudinal axis of the archwire 100, which can permit the archwire 100 to move in a direction that is substantially the same as the longitudinal axis of the archwire 100.

[0153] In some variants, the shaping system 810 can communicate to the actuator 866 how to move the sled 838 forwards or backwards along the rail 864 such that the holder 832 is positioned appropriately to engage with (e.g., hold) a portion of the archwire 100 at the correct location. In some variants, the shaping system 810 can communicate to the actuator 866 how to move the sled 838 forwards or backwards along the rail 864 after the holder 832 engages with a portion of the archwire 100 such that the archwire 100 is advanced and / or retracted along the rail 864 with the holder 832. In some variants, the holder 832 can be movable along an axis substantially perpendicular to the longitudinal axis of the rail 864 and / or archwire 100.

[0154] In some variants, after the holder 832 holds (e.g., engages, with, grips, holds, supports, retains, secures, grasps) a portion of the archwire 100, the actuator 866 can move the sled 838 and holder 832 along the rail 864 away from the holder 814 such that the archwire 100 moves with the holder 832 and / or sled 838 (see FIG. 11). In some variants, the holder 814 can release (e.g., disengage, lose contact with, disconnect) the archwire 100 as the actuator 866 moves the holder 832 and / or sled 838 away from the holder 814. In some variants, the actuator 866 can move the sled 838 with the holder 832 holding the archwire 100 forward or backward to position the archwire 100 and / or connectors 102 of the archwire 100 for grasping by a holder 844 and / or the gripper 850.

[0155] The shaping system 810 can include a holder 844 (e.g., gripper, fastener, vise, clasp, clamp). The holder 844 can engage with (e.g., grip, hold, support, retain, secure, grasp) a portion of the archwire 100 (see FIG. 11), for example, a connector 102 of the archwire 100. The holder 844 can be positioned to receive a portion (e.g., connector 102) of the archwire 100. Forexample, the holder 844 can be positioned to receive the archwire 100 as the archwire 100 held by the holder 832 is moved forward by the actuator 866. The holder 844 can be automatically and / or manually actuated to grasp a portion of the archwire 100. The shaping system 810 can move the archwire 100 to position the archwire 100 such that the holder 844 can engage with the appropriate portion of the archwire 100. In some variants, the archwire 100 can be moved by the actuator 866. In some variants, the archwire 100 can move with the holder 832 as the holder 832 and / or sled 838 are advanced and / or retracted along the rail 864 by the actuator 866. In some variants, the actuator 866 can advance and / or retract (e.g., move forward and / or backward) the archwire 100, holder 832, and / or sled 838 to position the archwire 100 and / or connectors 102 of the archwire 100 for grasping by the holder 844. In some variants, the holder 844 can be positioned above the rail 864 and / or surface 894. In some variants, the holder 844 can be coupled to the surface 894. In some variants, the holder 844 can be stationary. In some variants, the holder 844 can be movable. In some variants, the holder 844 can be suspended above the rail 864. In some variants, the holder 844 can be coupled to a frame, which can have an arch shape, to position the holder 844 above the rail 864. The holder 844, in some variants, can be centered about a central longitudinal plane of the rail 864.

[0156] In some variants, the holder 844 can hold (e.g., grip, retain, secure, grasp) a connector 102 of the archwire 100 adjacent the connector 102 held by the gripper 850. In some variants, the holder 844 can hold one connector 102 of the archwire 100 and the gripper 850 of the robot 874 can be actuated to grasp another adjacent connector 102 of the archwire 100. This can allow the holder 844 to anchor a connector 102 of the archwire 100 with the holder 844 as the gripper 850 moves an adjacent connector 102 to a position that corresponds to a digital marker, digital bracket, and / or tooth in the digital model with the teeth in the planned alignment. In this manner, the shaping system 810 can custom shape an interproximal segment 104 (e.g., loop) of the archwire 100 between the connector 102 held by the holder 844 and the adjacent connector 102 held by the gripper 850. The holder 844 can automatically engage and / or disengage with a connector 102 of the archwire 100 to selectively hold and / or release one or more connectors 102 of the archwire 100.

[0157] The shaping system 810 can include an energy application device 856, which can be a heat gun, electrode, and / or any other suitable device, to set (e.g., heat set) the archform 100 in a custom nonplanar shape. The energy application device 856 can be activated once the gripper 850 has repositioned a connector 102 of the archwire 100 to set the interproximal segment104 of the archwire 100 between the connector 102 held by the holder 844 and the adjacent connector 102 held by the gripper 850 such that the relative positioning between the connector 102 held by the holder 844 and the connector 102 held by the gripper 850 is the memorized (e.g., default) configuration of the interproximal segment 104.

[0158] In some variants, the energy application device 856 (e.g., heating device) can be disposed below the holder 844. In some variants, the energy application device 856 can be positioned above the surface 894 and / or rail 864. In some variants, the energy application device 856 can be coupled to the surface 894. In some variants, the energy application device 856 can be coupled to the robot 874, which can at least include the fifth member 892 and / or gripper 850. In some variants, the energy application device 856 can be mounted on a frame and / or stand, which can space the energy application device 856 away from the surface 894. The energy application device 856 can be automatically activated and / or deactivated to set the archwire 100 and / or an interproximal segment 104 of the archwire. In some variants, the energy application device 856 can activate for different lengths of time and / or at different levels of intensity based on the thickness, rigidities, and / or material characteristics of the archwire 100. When the energy application device 856 includes an electrical current system (e.g., electrode), the electrode can approach proximate the archwire 100, which can include contacting the archwire 100, and apply an electrical current thereto, which can raise the local temperature of the archwire 100 to heat set the local portion of the archwire 100 in the custom nonplanar shape.

[0159] In some variants, operation of the energy application device 856 can be controlled by an energy application device control panel 858. In some variants, a user can alter the operation of the energy application device 856, for example, changing energy (e.g., temperature) output by the energy application device 856, through the energy application device control panel 858. In some variants, a user can alter the operation of the energy application device 856 through the user interface 806. In some variants, operation of the energy application device 856 can automatically be adjusted by inputting characteristics of the archwire 100 into the energy application device control panel 858 and / or the user interface 806.

[0160] In some variants, the shaping system 810 can include a cooling device 860, for example, an air dispenser, fan, etc. The cooling device 860 can, in some variants, be activated to cool the archwire 100 and / or portions thereof after being heated by the energy application device 856. In some variants, the cooling device 860 can be activated after an interproximal segment 104 has been set by the energy application device 856 to cool the interproximal segment 104, forexample by dispensing air. In some variants, the cooling device 860 can be positioned above the surface 894 and / or rail 864. In some variants, the cooling device 860 can be disposed below the holder 844. In some variants, the cooling device 860 can be coupled to the surface 894. In some variants, the cooling device 860 can be coupled to the robot 874, which can at least include the fifth member 892 and / or gripper 850. In some variants, the cooling device 860 can be disposed proximate the energy application device 856, which can include being coupled to the frame supporting the energy application device 856. The cooling device 860 can be automatically activated and / or deactivated by the shaping system 810 to cool the archform 100 and / or an interproximal segment 104 of the archform 100.

[0161] The shaping system 810 can include a vision system 840. The visions system 840 can include one or more sensors, which can include camera, laser, LIDAR, infrared, depth, ultrasonic, photoelectric, spectral, proximity, environmental, and / or others. The vision system 840 can determine the position, orientation, and / or movement of the archwire 100 as the archwire 100 is held by the holder 814 and / or moves with the holder 832 and / or sled 838. The vision system 840 can capture visual data (e.g., scan) regarding the geometry, positioning, and / or orientation of the archwire 100 as the archwire 100 is held by the holder 814 and / or moves with the holder 832. The visions system 840 can be oriented with a field of view directed toward the movement path of the holder 832 such that, as the holder 832 passes through the field of view of the vision system 840 with the archwire 100, the vision system 840 can capture visual data for the archwire 100. The vision system 840 can be aimed at the archwire 100. The vision system 840 can be positioned adjacent a lateral side of the rail 864. The vision system 840 can be oriented such that it points in a direction substantially perpendicular to the longitudinal axis of the archwire 100 in the holder 832 such that the vision system 840 faces a lateral side of the archwire 100. The vision system 840 can be oriented such that is points in a direction substantially perpendicular to the longitudinal axis of the rail 864 such that as the archwire 100 moves along the rail 684, the archwire 100 moves in a direction substantially perpendicular to the direction the vision system 840 is pointed. This can advantageously improve the ability of the vision system 840 to distinguish the position, orientation, and movement of the archwire 100. The vision system 840 can be positioned at a sufficient distance from the rail 864 and / or holder 832 movement path such that the vision system 840 can see the entirety of the archwire 100 as the archwire 100 travels along a length of the rail 864. The vision system 840 can be positioned at a similar height to the archwire 100 in the holder 832. The vision system 840 can be coupled to the surface 894. The vision system 840 can bepositioned above the surface 894. The vision system 840 can be disposed on a frame, which can support the vision system 840 at an elevation (e.g., elevation above the surface 894, elevation of path of holder 832). The visual data captured by the vision system 840 can be used by the shaping system 810 to determine the geometry, positioning, and / or orientation of the archwire 100 to precisely operate the actuator 866, holder 832, holder 844, robot 874, gripper 850 of the robot 874, and / or other features to accurately custom shape the archwire 100 pursuant to a digital plan. In some variants, the visual data for the archwire 100 captured by the vision system 840 of the shaping system 810 can be compared against data for the archwire 100 provided to the shaping system 810, which can be used to verify that the loaded archwire 100 is the correct archwire to be currently shaped by the shaping system 810 and / or if the loaded archwire 100 has been damaged and should not be custom shaped.

[0162] In some variants, the vision system 840 can alert a user if the archwire 100 is not positioned and / or oriented correctly in the holder 832. In some variants, the vision system 840 can communicate the geometry, position, orientation, and / or movement of the archwire 100 to the shaping system 810. The shaping system 810 can use the archwire 100 position, orientation, and / or movement data communicated by the vision system 840 to determine appropriate actions and movements to be undertaken by the shaping system 810 to custom 3D shape the archwire 100. For example, the archwire 100 position, orientation, and / or movement data can be used to determine how to advance and / or retract the sled 838 such that the archwire 100 is positioned appropriately for engagement by the holder 844 and / or gripper 850. The archwire 100 position, orientation, and / or movement data can be used to determine when the holder 844 should be actuated to engage and / or disengage to hold and / or release the appropriate portion (e.g., a connector 102) of the archwire 100. The position, orientation, and / or movement data for the archwire 100 can be used to determine the appropriate movements of the robot 874 and / or the gripper 850 such that the gripper 850 can engage and / or disengage to hold and / or release the appropriate portion (e.g., a connector 102) of the archwire 100.

[0163] The shaping system can include a panel 842 (e.g., surface, screen, background), as shown in FIG. 10. The panel 842 can provide a backdrop for the vision system 840 as the holder 832 holding the archwire 100 is moved forward and / or backward along the rail 864. The field of view of the vision system 840 can be directed at the panel 842. The movement path of the holder 832 can pass between the vision system 840 and the panel 842, which can place an archwire 100 held by the holder 832 in the field of view of the vision system 840 between thevision system 840 and the panel 842. The panel 842 can be positioned proximate a lateral side of the archwire 100 opposite the vision system 840 such that the archwire 100 is positioned between vision system 840 and the panel 842. The panel 842 can be oriented to extend in substantially the same direction as the archwire 100 when the archwire 100 is loaded into the holder 814 and / or holder 832. The panel 842 can be substantially parallel to the rail 864. The panel 842 can be oriented substantially perpendicular to the direction the vison system 840 is aimed. The panel 842 can be a different color than the archwire 100, for example a color with high contrast to the color of the archwire 100. The panel 842 can provide a background and / or backdrop for the vision system 840 aimed at the archwire 100 such that the vision system 840 can more easily differentiate the archwire 100 from the surrounding environment. This can allow the vision system 840 to more easily and / or reliably determine the geometry (e.g., edge detection), position, orientation, and / or movement of the archwire 100.

[0164] In some variants, the shaping system 810 can include a temperature sensor 862 (e.g., a thermocouple or thermometer) that can detect a temperature. In some variants, the shaping system 810 can include more than one temperature sensors to detect temperatures at various locations about the shaping system 810. In some variants, the temperature sensor 862 can detect temperature proximate the shaping location for the archwire 100 (e.g., location where the holder 844 and gripper 850 will cooperatively custom shape the archwire 100), holder 844, and / or energy application device 856. The temperature sensor 862 can alert the shaping system 810 and / or the user when the measured temperature exceeds or drops below a predetermined threshold. In some variants, the shaping system 810 can automatically stop operations if the temperature measured by the temperature sensor 862 exceeds a predetermined threshold. In some variants, the temperature sensor 862 can be disposed above and / or proximate to the holder 844. In some variants, the temperature sensor 862 can be coupled to the holder 844 and / or frame supporting the holder 844. In some variants, the temperature sensor 862 can be coupled to the surface 894. In some variants, the temperature sensor 862 can be coupled to the robot 874, which can at least include the fifth member 892 and / or gripper 850. The temperature sensor 862 can be automatically activated and / or deactivated during operation of the shaping system 810.

[0165] In some variants, the shaping system 810 can include a housing 868, for example a flexible tube. In some variants, the housing 868 can at least partially house wiring of the shaping system 810 to reduce the risk of wiring catching on moving parts of the shaping system 810 during operation. In some variants, the housing 868 can be positioned adjacent therail 864. In some variants, the housing 868 can be made of a flexible material. In some variants, the housing 868 can be made of a rigid material. In some variants, the housing 868 can be coupled to the surface 894. In some variants, the housing 868 can house wiring connected to the holder 814, holder 832, vision system 828, sled 838, holder 844, temperature sensor 862, and / or actuator 866. In some variants, the housing 868 can house wiring providing energy and / or instruction to the holder 832 and / or vision system 828. The housing 868 can be flexible to accommodate the forward and / or backward movement of the holder 832 and / or visions system 828 along the rail 864. In some variants, the housing 868 can house wiring providing energy and / or instructions.

[0166] In some variants, the shaping system 810 can include a thermal camera 870. The thermal camera 870 can be aimed at the custom shaping location for the archwire 100, which can include the location where the holder 844 and gripper 850 cooperatively custom shape the archwire 100 for heat setting by the energy application device 856. The thermal camera 870 can be aimed at the holder 844. The thermal camera 870 can be aimed at the archwire 100, which can include an interproximal segment 104 of the archwire 100 between a connector 102 held by the holder 844 and an adjacent connector 102 held by the gripper 850. The thermal camera 870 can detect a temperature of the archwire 100 (e.g., the interproximal segment 104, connectors 102 adjacent the interproximal segment 104, holder 844, and / or gripper 850), which can include detecting while the interproximal segment 104 is being heat set to determine whether the interproximal segment 104 has reached a threshold shape setting temperature. In some variants, the thermal camera 870 can generate a heat map, which can be viewed by the operator (e g., which can include being viewed using the user interface 806). In some variants, the shaping system 810 can automatically turn off the energy application device 856 once the thermal camera 870 detects that the interproximal segment 104 and / or adjacent connectors 102 have reached the threshold shape setting temperature. In some variants, the thermal camera 870 can alert the shaping system 810 and / or the user if the archwire 100 (e.g., interproximal segment 104) and / or component of the shaping system 810 exceeds a safety threshold temperature. In some variants, the shaping system 810 and / or the energy application device 856 can automatically turn off and / or cease operation when the thermal camera 870 detects that the archwire 100 (e.g., interproximal segment 104) and / or component of the shaping system 810 has exceeded a safety threshold temperature.

[0167] In some variants, the shaping system 810 can include a tray 872 (e.g., surface, elevated surface, platform, podium, etc.). When the shaping system 810 has finished shaping the archwire 100 to a custom 3D shape, the gripper 850 of the robot 874 can hold the archwire 100and transfer the archwire 100 to the tray 872, which can be the location where the archwire 100 cools. The archwire 100 can remain on the tray until it has sufficiently cooled for a user to remove the archwire 100. In some variants, the shaping system 810 can include a vision system pointed at the tray 872 to capture visual data for the custom 3D shaped archwire 100, which can be used by the shaping system 810 to confirm that the custom 3D shaped archwire 100 was shaped correctly (e.g., corresponds to the digital plan). In some variants, a temperature sensor and / or thermal camera can monitor a temperature of the custom 3D shaped archwire 100 on the tray 872 and, upon detecting that the temperature reaches a lower threshold, the shaping system 810 can generate a notification for the user.

[0168] FIGS. 12 and 13 illustrate an enlarged view of the holder 814 of the shaping system 810 that can hold a portion of the archwire 100 during a startup process. The holder 814 can engage (e.g., grip, hold, support, retain, secure, grasp) the archwire 100, which can include a holding portion 827 (e.g., tag, flag, archwire portion) coupled to (e g., integrally formed with) the archwire 100, to maintain the position and / or orientation of the archwire 100. The holding portion 827 can be integral with the archwire 100. The holding portion 827 and the remainder of the archwire 100 can be cut together from the sheet of material. The holding portion 827 can provide a feature to be grasped by features (e.g., holder 814, holder 832) of the shaping system 810 to facilitate handling by the shaping system 810. After the archwire 100 is custom 3D shaped by the shaping system 810, the holding portion 827 can be separated (e.g., cut) from the archwire 100. The holding portion 827 can be removed from the archwire 100 prior to installation in a patient’s mouth. The holding portion 827, in some variants, can be referred to as part of the archwire 100. The holding portion 827 can extend from an end (e.g., end connector 102) of the archwire 100. In some variants, the holding portion 827 can be integrally formed with the archwire 100. In some variants, the holding portion 827 can be removably connected to the archwire 100. In some variants, the holding portion 827 can be made of the same material as the archwire 100. In some variants, the holding portion 827 can be made of a different material than the archwire 100. In some variants, the holding portion 827 can be substantially planar. In some variants, the holding portion 827 can have the same thickness as the archwire 100. In some variants, the archwire 100 does not include a holding portion 827 and the features (e.g., holder 814, holder 832) of the shaping system 810 can grasp a connector 102 of the archwire 100 for handling. The holding portion 827 can include a standard size and / or shape across all archwires 100 to be customshaped by the shaping system 810, which can improve repeatable loading despite differences in archwires 100.

[0169] A user can load the archwire 100 (e.g., holding portion 827 and / or connector 102) into the holder 814. With the archwire 100 received by the holder 814, the archwire 100 can extend away from the holder 814. The position and / or orientation of the archwire 100 can be maintained by the holder 814 (see FIG. 13). In some variants, the holder 814 can be a clamp and / or vise. The holder 814 can include a contact member 818 (e.g., block, jaw, movable member), one or more biasing members 820 (e.g., spring(s)), a handle 816 (e.g., rod, bar, member, grip), and / or a slot 822 (e.g., channel, receiving space). FIG. 12 illustrates the holder 814 in an open position with the contact member 818 raised, counter to a downward force of the one or more biasing members 820, to enable a user to insert and / or remove the archwire 100 (e.g., holding portion 827 and / or connector 102) from the holder 814. FIG. 13 illustrates the holder 814 in a closed position where the holding portion 827 of the archwire 100 is engaged by the holder 814 such that the position and / or orientation of the archwire 100 is maintained.

[0170] The slot 822 of the holder 814 can be shaped to receive the archwire 100 (e.g., holding portion 827 and / or connector 102). The slot 822 can extend in a direction substantially parallel to the longitudinal axis of the rail 864. In some variants, the slot 822 can be substantially colinear with a central longitudinal plane of the rail 864. The slot 822 can include two side walls, a back wall, and / or a bottom wall such that the archwire 100, such as the holding portion 827 and / or connector 102, can only be inserted and / or removed from the slot 822 from the front of the holder 814. This can advantageously increase the stability of the archwire 100 while it is held by the holder 814. The slot 822 can include a tapered portion that can guide the archwire 100 into the slot 822 as the operator loads the archwire 100 into the holder 814. The width of the slot 822 can be slightly larger than the width of the archwire 100 to prevent substantial movement of the archwire 100 within the slot 822. In some variants, the width of the slot 822 can be adjusted (e.g., made smaller or larger).

[0171] The contact member 818 can contact the archwire 100 (e.g., holding portion 827 and / or connector 102) when the holder 814 is in the closed position to secure the archwire 100 within the slot 822. The contact member 818 can move downward from the force of the one or more biasing members 820 to apply a downward force to the top of the archwire 100 (e.g., holding portion 827 and / or connector 102) protruding out of a top of the slot 822. The contact member 818 can be a block. The contact member 818 can exert a pushing force on the archwire100 (e.g., holding portion 827 and / or connector 102). The contact member 818 can contact a top surface of the archwire 100 (e g., holding portion 827 and / or connector 102). The contact member 818 can exert a downward force on the archwire 100 (e.g., holding portion 827 and / or connector 102) to push the archwire 100 (e.g., holding portion 827 and / or connector 102) into the slot 822 of the holder 814 such that the archwire 100 (e.g., holding portion 827 and / or connector 102) is secured by the holder 814 in the closed position. In some variants, the contact member 818 can include a notch or channel located on a bottom of the contact member 818. The notch or channel can be shaped to receive the archwire 100 (e.g., holding portion 827 and / or connector 102), which can help prevent movement of the archwire 100 (e.g., holding portion 827 and / or connector 102) when secured within the slot 822 by the contact member 818.

[0172] The contact member 818 can be connected to a handle 816 such that the contact member 818 moves with the handle 816. A user can move the handle 816 upward to overcome a downward biasing force of the one or more biasing members 820 to place the contact member 818 in an open position, which can be a position in which the contact member 818 is moved away from the slot 822 to provide space to receive the archwire 100 (e.g., holding portion 827 and / or connector 102) within the slot 822. With the archwire 100 (e.g., holding portion 827 and / or connector 102) positioned in the slot 822, the operator can release the handle 816 to allow the downward biasing force of the one or more biasing members 820 to move the contact member 818 downward to contact and apply a downward force to the archwire 100 (e.g., holding portion 827 and / or connector 102) to secure the archwire 100 (e.g., holding portion 827 and / or connector 102) within the slot 822. In some variants, a user can move the handle 816 downward such that the contact member 818 moves downward and the holder 814 is transitioned to the closed position where the contact member 818 can contact the archwire 100 and / or holding portion 827. In some variants, the holder 814 is disposed toward the closed position, such that if a user releases the handle 816, the handle 816 and the contact member 818 will move downward to the closed position.

[0173] In some variants, the holder 814 is disposed toward the closed position by one or more biasing members 820. The one or more biasing members 820 can be springs. The one or more biasing members 820 can exert a downward force on the contact member 818 to bias the contact member 818 downward to transition the holder 814 into the closed position.

[0174] A user can load an archwire 100 (e.g., holding portion 827 and / or connector102) into the holder 814 to be custom shaped by the shaping system 810. A user can transitionthe holder 814 to the open position by moving the handle 816 upward such that the contact member 818 is lifted upward, against the downward biasing force of the one or more biasing members 820), to open the slot 822 as shown in FIG. 12. The user can insert the archwire 100 (e.g., holding portion 827 and / or connector 102) into the slot 822. The user can release the handle 816 to allow the contact member 818 to move downward and contact the archwire 100 (e.g., holding portion 827 and / or connector 102), holding the archwire 100 (e.g., holding portion 827 and / or connector 102) in place between the contact member 818 and the slot 822 such that the position and / or orientation of the archwire 100 is maintained as shown in FIG. 13.

[0175] In some variants, the holder 814 can be stationary. The holder 814 can be coupled to the surface 894. In some variants, the holder 814 can be movable. In some variants, the actuator 866 can advance and / or retract the holder 814 such that the archwire 100 moves with the holder 814. In some variants, more than one archwire 100 can be loaded into the holder 814 at a time to be shaped by the shaping system 810. For example, the holder 814 can include multiple slot 822 and contact members 818 to receive multiple archwires 100 (e.g., holding portions 827 and / or connectors 102).

[0176] FIG. 14A illustrates the holder 814 and the holder 832 of the shaping system 810 holding the holding portion 827 of the archwire 100. As illustrated, the vision system 828 (e.g., smart vision system with feature detection) can determine if the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly held by the holder 814 for shaping by the shaping system 810. The vision system 828 can determine the position and / or orientation of the archwire 100 (e.g., holding portion 827 and / or connector 102) after the archwire 100 (e.g., holding portion 827 and / or connector 102) has been loaded into the holder 814 by a user. The shaping system 810, based on the detections by the vision system 828, can notify the user if the archwire 100 (e.g., holding portion 827 and / or connector 102) has been properly loaded into the holder 814. In some variants, the vision system 828 can include a laser detection system, which can emit and receive a laser. The vision system 828 can be aimed at a portion of the archwire 100 (e.g., holding portion 827 and / or connector 102) that extends from the slot 822. In some variants, the vision system 828 can be orientated such that it is aimed in a direction substantially perpendicular to the longitudinal axis of the archwire 100 loaded in the holder 814. In some variants, the vision system 828 can be aimed at a planar side of the archwire 100 (e.g., holding portion 827 and / or connector 102). In some variants, the archwire 100 (e.g., holding portion 827 and / or connector 102) can include one or more features to assist the vision system 828 in determining the position and / or orientation ofthe archwire 100 (e.g., holding portion 827 and / or connector 102). For example, the holding portion 827 and / or other feature of the archwire 100 can include a graphic, symbol, pattern, cutout, notch, groove, recess, scratch, and / or other features for detection by the vision system 828. In some variants, the holding portion 827 and / or other feature of the archwire 100 can include a feature 898 that can be detected (e.g., seen, scanned) by the vision system 828 as shown in FIG. 14B. The feature 898 can be a cut out (e.g., notch, recess), which can form an angle (e.g., ninety degree angle), in the holding portion 827. The vision system 828 can detect whether the feature 898 is in the correct position, which can include orientation, to determine if the archwire 100 was loaded correctly into the holder 814. In some variants, the vision system 828 can detect the edge of the feature 898 to determine correct orientation, which can include utilizing a laser. Based on the detected positioning and / or orientation of the feature by the vision system 828, the shaping system 810 can determine whether the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly loaded into the holder 814. A proper loading can correspond to a planar face of the archwire 100 (e.g., holding portion 827 and / or connector 102) being perpendicularly oriented relative to the vision system 828 (e.g., laser of the vision system 828), the archwire 100 (e.g., holding portion 827 and / or connector 102) contacting a rear wall of the slot 822, the archwire 100 (e.g., holding portion 827 and / or connector 102) being level (e.g., not tilted, parallel relative to the surface 894, bottom surface of holding portion 827 resting on bottom surface of the slot 822, top surface of the holding portion 827 contacting the bottom surface of the contact member 818, etc.), and / or the archwire 100 (e.g., holding portion 827 and / or connector 102) being seated in the slot 822.

[0177] In some variants, the vision system 828 can include one or more arm(s) 899, 900, which can also be referred to as members. The one or more arm(s) 899, 900 can include features (e.g., emitters, receivers, transceivers, and / or other features) to detect the position, orientation, and / or geometry of the archwire 100. The vision system 828 can include a laser 830 that spans from one of the one of the arms(s) 899, 900 to the other of the arm(s) 899, 900 to determine if the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly held by the holder 814 for shaping by the shaping system 810 and / or if the archwire 100 is oriented and / or positioned properly for shaping by the shaping system 810. The one or more arm(s) 899, 900 can be positioned on opposing lateral sides of the archwire 100 when the archwire 100 (e.g., holding portion 827 and / or connector 102) has been loaded into the holder 814. The one or more arm(s) 899, 900 can be disposed on opposing sides of a central plan of the holder 814 and / orholder 832. In some variants, the one or more arm(s) 899, 900 can be orientated to extend longitudinally in a direction substantially perpendicular to the longitudinal axis of the archwire 100 loaded in the holder 814. In some variants, the laser 830 emitted from the one or more arms 899, 900 can be aimed at a planar side of the archwire 100 (e.g., holding portion 827 and / or connector 102). In some variants, the arm 899 and / or the arm 900 can include a laser transceiver to transmit and receive a laser 830. In some variants, the arm 899 and / or the arm 900 can include a laser transmitter and / or a laser receiver to transmit and / or receive a laser 830. In some variants where there are two arms 899, 900, one of the arms 899, 900 can include a laser transmitter while the opposing arm 899, 900 can include a laser receiver. In some variants, the laser 830 can be transmitted by an arm 899, 900 and be at least partially received by the same arm 899, 900 that transmitted the laser 830 after the laser 830 at least partially reflects off the archwire 100 (e.g., holding portion 827 and / or connector 102). In some variants, the laser 830 can be transmitted by an arm 899, 900 and be at least partially received by the opposing arm 899, 900. In some variants, both arms 899, 900 can transmit and / or receive a laser 830. In some variants, the vision system 828 can determine the position and / or orientation of the archwire 100 (e.g., holding portion 827 and / or connector 102) based on the laser data transmitted and / or received by the features of the arm 899 and / or the arm 900 to determine whether the archwire 100 (e g., holding portion 827 and / or connector 102) is properly held by the holder 814. In some variants, the vision system 828 can determine whether the archwire 100 (e.g., holding portion 827 and / or connector 102) has been properly loaded into the holder 814 by a user. In some variants, the vision system 828 can alert the shaping system 810 and / or the user if the archwire 100 (e.g., holding portion 827 and / or connector 102) has not been properly loaded. In some variants, the vision system 828 can communicate position and / or orientation data for the archwire 100 (e.g., holding portion 827 and / or connector 102) to the shaping system 810. The shaping system 810 can utilize this data to position the holder 832 such that the holder 832 grasps the archwire 100 (e.g., holding portion 827 and / or connector 102) at the correct position (e.g., holding portion 827). In some variants, the actuator 866 can advance and / or retract the sled 838 to move the holder 832 to the correct position for engagement. In some variants, the vision system 828 and / or the one or more arm(s) 899, 900 can be moved independently of the holder 832. In some variants, the one or more arm(s) 899, 900 can move independently of each other. In some variants, the vision system 828 and / or the one or more arm(s) 899, 900 can be coupled to the sled 838. In some variants, the one or more arm(s) 899, 900 can move relative to the sled 838.

[0178] The holder 832 can be actuated to hold (e.g., clamp, engage with, grasp) the archwire 100 (e.g., holding portion 827 and / or connector 102). The holder 832 can include a first jaw 834 (e.g., engagement portion) and a second jaw 836 (e.g., engagement portion). In some variants, the first jaw 834 and the second jaw 836 can be movable toward and away from each other. In some variants, only one of the first jaw 834 and the second jaw 836 can be movable. The first jaw 834 and the second jaw 836 can oppose each other. The first jaw 834 and the second jaw 836 can be positioned on opposing sides of the projected central longitudinal plane of the slot 822 of the holder 814. The first jaw 834 and the second jaw 836 can be positioned on opposing lateral sides of the archwire 100 when held by the holder 814. The first jaw 834 and the second jaw 836 can have contact surfaces that can contact the archwire 100 (e.g., holding portion 827 and / or connector 102). The contact surfaces of the first jaw 834 and second jaw 836 can be substantially parallel to the lateral sides of the archwire 100 (e.g., holding portion 827 and / or connector 102). The holder 832 can be movable between a closed position where the first jaw 834 and second jaw 836 contact the archwire 100 (e.g., holding portion 827 and / or connector 102) and an open position where the first jaw 834 and second jaw 836 do not contact the archwire 100 (e.g., holding portion 827 and / or connector 102). The shaping system 810 can instruct the holder 832 and / or actuator 866 to move the holder 832 in the open position such that the first jaw 834 and the second jaw 836 are positioned at the correct location (e.g., at the holding portion 827 or connector 102) to hold the archwire 100, for example, based on data from the vision system 828. With the holder 832 correctly positioned, either or both the first jaw 834 and / or the second jaw 836 can be actuated toward a closed position such that the archwire 100 (e.g., holding portion 827 and / or connector 102) is held between the first jaw 834 and the second jaw 836 in the closed position. In some variants, the archwire 100 (e.g., holding portion 827 and / or connector 102) can be loaded into the holder 814 with the holder 832 open and positioned to receive the archwire 100 (e.g., holding portion 827 and / or connector 102) between the first jaw 834 and the second jaw 836 such that, with the archwire 100 properly loaded into the holder 814, the holder 832 can actuate to close to grasp the archwire 100 (e.g., holding portion 827 and / or connector 102) without moving the sled 838.

[0179] In some variants, the vision system 828 and / or the one or more arm(s) 899, 900 can move after the holder 832 holds the archwire 100 (e.g., holding portion 827 and / or connector 102) to determine if the archwire 100 (e.g., holding portion 827 and / or connector 102) is correctly held by the holder 832. In some variants, the vision system 828 and / or the one or more arm(s)899, 900 can determine if the archwire 100 (e.g., holding portion 827 and / or connector 102) is correctly held by the holder 832 by detecting the position and / or orientation of feature 898 to determine whether the feature 898 is in the correct position and / or orientation. In some variants, the vision system 828 and / or one or more arms 899, 900 can linearly translate away from the holder 814 along a length of the archwire 100 when the archwire 100 (e.g., holding portion 827 and / or connector 102) is held by the holder 832 to determine the position and / or orientation of feature 898, which can indicate the position and / or orientation of the archwire 100. A proper holding by the holder 832 can correspond to a planar face of the archwire 100 (e.g., holding portion 827 and / or connector 102) being perpendicularly oriented relative to laser 830 of the vision system 828, the archwire 100 (e g., holding portion 827 and / or connector 102) being level (e.g., not tilted, parallel relative to the surface 894, parallel relative to the sled 838, etc.), and / or the holder 832 gripping the archwire 100 (e.g., holding portion 827 and / or connector 102) at a predetermined distance from the feature 898, the holder 814, and / or a connector 102. In some variants, the vision system 828 and / or the one or more arm(s) 899, 900 can move with the holder 832 and / or the archwire 100 to determine (e.g., continuously determine) that the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly held by the holder 832, which can include determining the position and / or orientation of the archwire 100 (e.g., feature 898). In some variants, the vision system 828 can move independently of the holder 832 and / or the archwire 100 to determine (e.g., continuously determine) that the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly held by the holder 832. In some variants, the movement of the vision system 828 and / or the one or more arms 899, 900 can be automatic. In some variants, the vision system 828 can scan the archwire 100 loaded into the holder 814, prior to the holder 832 grasping the archwire 100 (e.g., holding portion 827 and / or connector 102), to instruct the shaping system 810 regarding the geometry, positioning, and / or orientation of the archwire 100 to guide movement of the holder 832 to grasp the archwire 100 at a target location (e.g., holding portion 827 and / or connector 102). In some variants, the vision system 828, which can include the one or more arm(s) 899, 900, can move independently (e.g., be translated linearly independently) of the holder 832 prior to the holder 832 grasping the archwire 100 (e.g., holding portion 827 and / or connector 102).

[0180] In some variants, the movement of the actuator 866, the holder 832, the first jaw 834, and / or the second jaw 836 can be automatic. In some variants, the holder 832 can hold the archwire 100 (e.g., holding portion 827 and / or connector 102) away from where the holder814 holds the archwire 100 (e g., holding portion 827 and / or connector 102). In some variants, the holder 814 and the holder 832 can both hold onto the holding portion 827. In some variants, the holder 832 is disposed toward the closed position by biasing members such as springs. In some variants, the holder 832 can be moveable between the open and closed positions by electronic actuator(s), spring(s), pneumatic(s), hydraulic(s), and / or electric motor(s).

[0181] FIGS. 15-17 illustrate enlarged views of features of the shaping system 810 during operation. As described previously, a user can load the archwire 100 (e.g., holding portion827 and / or connector 102) into the holder 814 such that the position and / or orientation of the archwire 100 is maintained. The vision system 828 can detect the position and / or orientation of the archwire 100, which can be based on a detected feature of the archwire 100. The vision system828 can relay this information to the shaping system 810, and the shaping system 810 can instruct the actuator 866 to advance and / or retract the sled 838 to move the holder 832 such that the holder 832 is positioned correctly to hold a portion of the archwire 100 (e g., holding portion 827 and / or connector 102). Once the holder 832 is positioned correctly, the holder 832 can hold (e.g., grip, clamp, pinch) the portion of the archwire 100 (e.g., holding portion 827 and / or connector 102). In some variants, the shaping system 810 can position the holder 832 for grasping the portion of the archwire 100 (e.g., holding portion 827 and / or connector 102) prior to the archwire 100 being loaded into the holder 814 and / or the vision system 828 detecting that the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly loaded into the holder 814, which can enable the holder 832 to be actuated closed by the shaping system 810 when the vision system 828 determines that the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly loaded into the holder 814 without movement of the sled 838. The holder 832 can acuate the first jaw 834 and second jaw 836 to grasp the archwire 100 (e.g., holding portion 827 and / or connector 102) when the vision system 828 determines that the archwire 100 (e.g., holding portion 827 and / or connector 102) is properly loaded into the holder 814.

[0182] With the holder 832 grasping the archwire 100 (e.g., holding portion 827 and / or connector 102), the shaping system 810 can move the holder 832 away from the holder 814 while holding the archwire 100 (e g., holding portion 827 and / or connector 102) (see FIG. 16 and 17), which can disengage (e.g., remove, pull) the archwire 100 (e.g., holding portion 827 and / or connector 102) from the holder 814. In some variants, the actuator 866 can move the sled 838 and / or the holder 832, which can be coupled to the sled 838, away from the holder 814. In some variants, the holder 814 can automatically release the archwire 100 (e g., holding portion827 and / or connector 102) as the holder 832 moves away from the holder 814. In some variants, the force required to pull the archwire 100 (e.g., holding portion 827 and / or connector 102) from the holder 814 is less than the force required to pull the archwire and / or the holding portion 827 from the holder 832 such that, as the holder 832 moves away from the holder 814, the archwire 100 (e.g., holding portion 827 and / or connector 102) is pulled from the holder 814 and travels with the holder 832.

[0183] The holder 832 with the archwire 100 can move to position one or more portions of the archwire 100, for example, one or more connectors 102, for engagement by the holder 844 and / or gripper 850 of the robot 874 (see FIGS. 16 and 17). In some variants, the actuator 866 can advance and / or retract the sled 838, holder 832, and / or archwire 100 held by the holder 832 to position one or more connectors 102 of the archwire 100 for holding (e.g., grasping, gripping, squeezing) by the holder 844 and / or gripper 850. As described herein, the holder 832 with the archwire 100 can pass between the vision system 840 and the panel 842, which can provide a backdrop to improve visual data collection regarding the archwire 100 by the vision system 840. The holder 832 with the archwire 100 can pass through the field of view of the vision system 840 so that the vision system 840 can capture visual data regarding the archwire 100, which can include the geometry, positioning, and / or orientation of the archwire 100. The visual data can inform and / or verify to the shaping system 810 the geometry, positioning, and / or orientation of the archwire 100. The shaping system 810 can compare the visual data captured by the vision system 840 for the archwire 100 with data regarding the archwire 100 provided to the shaping system 810 by the design system 400, scanning device 408, and / or clinician system 406.

[0184] The holder 844 can, in some variants, be in a fixed location. The holder 844 can include a first jaw 846 and a second jaw 848 that can be actuated open and closed. In some variants, the holder 844 can be a clamp and / or vise. In some variants, the first jaw 846 and the second jaw 848 can be movable toward or away from each other, which can include being actuated toward or away from each other. In some variants, only one of the first jaw 846 and the second jaw 848 can be movable. The first jaw 846 and second jaw 848 can be spaced apart from each other to receive the archwire 100 therebetween. The first jaw 846 and second jaw 848 can be moved toward each other to hold (e.g., clamp, grasp) the archwire 100 therebetween. The first jaw 846 and the second jaw 848, when open to receive the archwire 100 from the holder 832, can be positioned on opposing lateral sides of the archwire 100 such that the archwire 100 can bepositioned between the first jaw 846 and the second jaw 848. The first jaw 846 and the second jaw 848 can have a contact surface that can contact the archwire 100 and / or a connector 102 of the archwire 100. The contact surfaces of the first jaw 846 and second jaw 848 can be substantially parallel to the lateral sides of the archwire 100. The holder 844 can be actuated between a closed position where the first jaw 846 and second jaw 848 contact the archwire 100 and an open position where the first jaw 846 and second jaw 848 do not contact the archwire 100. In some variants, the holder 844 can be moveable between the open and closed positions by electric actuator(s), spring(s), pneumatic(s), hydraulic(s), and / or electric motor(s). The holder 832 can be positioned at a height to receive the archwire 100 as the holder 832 with the archwire 100 is advanced. The holder 832 with the archwire 100 can be advanced to position a connector 102, such as the second connector 102 from the end of the archwire 100, between the first jaw 846 and second jaw 848 of the holder 844. The shaping system 810, based on the movement of the holder 832 (e.g., movement of the sled 838, activity of the actuator 866), visual data captured by the vision system 840, and / or data regarding the archwire 100 provided to the shaping system 810, can determine when the target connector 102, such as the second connector 102, of the archwire 100 is positioned between the first jaw 846 and the second jaw 848. In some variants, the shaping system 810 can include a vision system or other sensor system that can determine when the target connector 102, such as the second connector 102, is positioned between the first jaw 846 and the second jaw 848. With the target connector 102, such as the second connector 102, positioned between the first jaw 846 and the second jaw 848, the holder 844 can actuate the first jaw 846 and / or second jaw 848 to grasp the target connector 102.

[0185] The gripper 850 of the robot 874 can include a first jaw 852 and a second jaw 854. In some variants, the gripper 850 can be a clamp, vise, and / or hand. In some variants, the first jaw 852 and the second jaw 854 can be movable toward and away from each other. In some variants, only one of the first jaw 852 and the second jaw 854 can be movable. The robot 874 can position the first jaw 852 and the second jaw 854 on opposing lateral sides of the archwire 100 such that the archwire 100 can be positioned between the first jaw 852 and the second jaw 854. The first jaw 852 and the second jaw 854 can have contact surfaces that can contact the archwire 100 (e.g., a connector 102). The robot 874 can position the contact surfaces of the first jaw 852 and second jaw 854 such that they are substantially parallel to the lateral sides of the archwire 100. The gripper 850 can be movable between a closed position where the first jaw 852 and second jaw 854 contact the archwire 100 and an open position where the first jaw 852 and second jaw854 do not contact the archwire 100. In some variants, the gripper 850 can be moveable between the open and closed positions by electric actuator(s), spring(s), pneumatic(s), hydraulic(s), and / or electric motor(s).

[0186] In some variants, the holder 832 and / or gripper 850 can include a variety of materials. For example, the holder 832 and / or gripper 850 can include one or more metals. In some variants, the holder 832 and / or gripper 850 can include one or more insulating materials, such as a ceramic. Incorporating one or more insulating materials can advantageously reduce the heat transfer between the holder 832 and / or gripper 850 and the archwire 100 when the archwire 100 is heated by the energy application device 856. For example, the one or more insulating materials can reduce a heat sink effect of the holder 832 and / or gripper 850 as the archwire 100 is heated by the energy application device 856. This can reduce the amount of energy required to heat portions of the archwire 100 to the required shape-setting temperature during the custom shaping process. It can also decrease the required time to heat set portions of the archwire 100 during the custom shaping process.

[0187] The holder 832 can move to position one or more portions of the archwire 100, for example, one or more connectors 102, for engagement by the holder 844 and / or gripper 850 of the robot 874 (see FIGS. 16-18). The robot 874 can maneuver the gripper 850 to position the first jaw 852 and second jaw 854 on opposing sides of a first connector 102 of the archwire 100 and actuate the first jaw 852 and / or second jaw 854 to the closed position to grasp the first connector 102. In some variants, the gripper 850 can grasp the first connector 102 before the holder 844 grasps the second connector 102. In some variants, the gripper 850 can grasp the first connector 102 after the holder 844 grasps the second connector 102. In some variants, the robot 874 can position the open gripper 850 such that the holder 832 can be advanced and / or retracted to position the first connector 102 in the open gripper 850. The robot 874 can move the gripper 850 holding a first connector 102 of the archwire 100 such that the first connector 102 is positioned relative to the second connector 102 at a location that corresponds to that of a corresponding digital marker in the digital model, which can place the interproximal segment 104 between the first and second connectors 102 in a custom nonplanar shape that is configured to move the patient’s teeth toward a digitally planned alignment. The energy application device 856 can then set the interproximal segment 104 between the first and second connectors 102, for example, by applying heat, such that the custom nonplanar shape is the default shape (e.g., memorized shape) of the interproximal segment 104. In some variants, the cooling device 860can cool the archwire 100 and / or the interproximal segment 104 as necessary, which can include cooling to room temperature before proceeding to shape the next interproximal segment 104. The gripper 850 can release the first connector 102 and the holder 844 can release the second connector 102. The holder 832 can be advanced to position a third connector 102, adjacent the second connector 102, in the open holder 844. In some variants, the holder 832 can be advanced to position the second connector 102 in the open gripper 850. In some variants, the robot 874 can move the open gripper 850 to place the second connector 102 therein, which can be after or before the holder 844 closes on the third connector 102.

[0188] With the third connector 102 positioned in the open holder 844, the holder 844 can be actuated closed on the third connector 102. With the second connector 102 positioned in the open gripper 850, the gripper 850 can be actuated closed on the second connector 102. The robot 874 can move the gripper 850 holding the second connector 102 of the archwire 100 such that the second connector 102 is positioned relative to the third connector 102 at a location that corresponds to that of a corresponding digital marker in the digital model, which can place the interproximal segment 104 between the second and third connectors 102 in a custom nonplanar shape that is configured to move the patient’s teeth toward a digitally planned alignment. The energy application device 856 can then set the interproximal segment 104 between the second and third connectors 102, for example, by applying heat, such that the custom nonplanar shape is the default shape (e.g., memorized shape) of the interproximal segment 104. The shaping system 810 can proceed accordingly until the entirety of the archwire 100 (e.g., all of the interproximal segments 104) is set in the custom nonplanar shape corresponding to the planned alignment of the patient’s teeth. In some variants, the shaping system 810 can skip shaping one or more interproximal segments 104. In some variants, the robot 874, as opposed to the holder 832, can move the archwire 100 to position connectors 102 in the open holder 844 for grasping.

[0189] In some variants, the movement, positioning, and / or actions of the holder 832, holder 844, gripper 850, robot 874, and / or other features of the shaping system 810 can be decided and / or influenced based on the position, orientation, and / or movement data of the archwire 100 acquired by the vision system 840 and / or another visions system. For example, the archwire 100 position, orientation, and / or movement data can be used to determine how to advance and / or retract the sled 838 such that the archwire 100 is positioned appropriately for engagement by the holder 844 and / or gripper 850. The archwire 100 position, orientation, and / or movement data can be used to determine when the holder 844 should engage and / or disengage to hold and / or releasethe appropriate portion of the archwire 100. The archwire 100 position, orientation, and / or movement data can be used to determine the appropriate movements of the robot 874 and / or the gripper 850 such that the gripper 850 can engage and / or disengage to hold and / or release the appropriate portion of the archwire 100. In some variants, the movement, positioning, and / or actions of the holder 832, holder 844, gripper 850, robot 874, and / or other features of the shaping system 810 can be determined and / or influenced through calculations performed by the shaping system 810 based on positioning and / or dimensional data of components of the shaping system 810. In some variants, the user can influence the movement, positioning, and / or actions of the holder 832, holder 844, gripper 850, robot 874, and / or other features of the shaping system 810 by inputting parameters relating to dimensions of the archwire 100.

[0190] In some variants, the shaping system unit 800 can include one or more vision system(s) 811 as shown in FIG. 9B, which can include one for each of the shaping systems 810, 812. The one or more the vision system(s) 811 can monitor features of the shaping systems 810, 812, which can include the moving features of the shaping systems 810, 812, and / or archwires 100. In some variants, the one or more the vision system(s) 811 can monitor temperatures, which can trigger one or more notifications when temperatures below or above thresholds are reached. The vision system 811 can verify the holder 844 and / or gripper 850 are holding the archwire 100 at the correct location, for example, at the appropriate location on one or more connectors 102. In some variants, the vision system 811 can determine the appropriate movement of the robot 874 such that the gripper 850 and held connector 102 are moved to the appropriate position corresponding to a digital marker in the digital model. In some variants, the vision system 811 can verify the robot 874 and the gripper 850 have moved a held connector 102 to the appropriate position corresponding to a digital marker in the digital model before the interproximal portion 104 is set using the energy application device 856. In some variants, the vision system 811 and / or another vision system can scan the archwire 100 as it is being custom 3D shaped to verify the archwire 100 is being shaped into the desired 3D shape. The vision system 811 can be disposed inside the housing 802, which can include being disposed on a wall of the housing 802 and / or an inside comer thereof. The vision system(s) 811, in some variants, can include a camera (e.g., webcam) to enable an operator to remotely monitor the shaping systems unit 800 (e.g., shaping systems 810, 812.

[0191] FIG. 19 illustrates an archform 100 on a tray 872 after the archform 100 has been shaped by the shaping system 810. Once the entirety of the archwire 100 is set in the customnonplanar shape, the gripper 850 can hold the archwire 100, and the robot 874 can move the gripper 850 to place the archwire 100 on the tray 872. The gripper 850 can release the archwire 100 such that the archwire 100 is deposited on the tray 872 for inspection, cooling, and / or removal from the shaping system unit 800. In some variants, the archwire 100 can be scanned on the tray 872 to determine whether it matches the desired 3D custom shape according to the digital plan.

[0192] The archwire 100 described herein can be heated to a variety of temperatures to be heat set. For example, the archwires 100 can be heated to between 200 and 700 degrees Celsius, which can include any value or range of values therebetween, to heat set the archwire 100. In some variants, the archwires 100 can be heated to between 390 and 550 degrees Celsius, which can include any value or range of values therebetween, to heat set the archwire 100. In some variants, the archwires 100 can be heated to between 400 and 500 degrees Celsius, which can include any value or range of values therebetween, to heat set the archwire 100.

[0193] The systems, methods, and / or devices described herein can significantly improve the manufacturing of archwires. For example, the systems, methods, and / or devices described herein can significantly improve the time to custom shape an archwire for a specific patient, which can reduce costs. The systems, methods, and / or devices described herein can significantly improve accuracy in custom shaping an archwire for a specific patient, which can improve patient outcomes.

[0194] The robots (e.g., automated machines, machines) described herein can include 6-axis robotics. In some variants, the grippers and / or clamps described herein can be pneumatic. In some variants, the actuators, such as the linear actuators, can include servos. In some variants, the operator, as opposed to the robot, can unload the archwire from the robot and place the archwire on the tray. The robots (e.g., automated machines, machines) described herein can, in some variants, have a repeatability range of + / -0.020-0.040 millimeters.

[0195] The shaping systems described herein can include lights and / or sound emitters to convey statuses to operators.

[0196] In general, the word “module,” as used herein, refers to logic embodied in hardware or firmware or to a collection of software instructions, having entry and exit points. Modules are written in a program language, such as JAVA, C or C++, Python, or the like. Software modules may be compiled or linked into an executable program, installed in a dynamic link library, or may be written in an interpreted language such as BASIC, PERL, LUA, or Python. Software modules may be called from other modules or from themselves, and / or may be invokedin response to detected events or interruptions. Modules implemented in hardware include connected logic units such as gates and flip-flops, and / or may include programmable units, such as programmable gate arrays or processors.

[0197] Generally, the modules described herein refer to logical modules that may be combined with other modules or divided into sub-modules despite their physical organization or storage. The modules are executed by one or more computing systems and may be stored on or within any suitable computer readable medium or implemented in-whole or in-part within special designed hardware or firmware. Not all calculations, analysis, and / or optimization require the use of computer systems, though any of the above-described methods, calculations, processes, or analyses may be facilitated through the use of computers. Further, in some embodiments, process blocks described herein may be altered, rearranged, combined, and / or omitted.

[0198] The computer system can include one or more processing units (CPU), which may comprise a microprocessor. The computer system can include a physical memory, such as random-access memory (RAM) for temporary storage of information, a read only memory (ROM) for permanent storage of information, and a mass storage device, such as a backing store, hard drive, rotating magnetic disks, solid state disks (SSD), flash memory, phase-change memory (PCM), 3D XPoint memory, diskette, or optical media storage device. Alternatively, the mass storage device may be implemented in an array of servers. Typically, the components of the computer system can be connected using a standards-based bus system. The bus system can be implemented using various protocols, such as Peripheral Component Interconnect (PCI), Micro Channel, SCSI, Industrial Standard Architecture (ISA) and Extended ISA (EISA) architectures.

[0199] The computer system can include one or more input / output (I / O) devices and interfaces, such as a keyboard, mouse, touch pad, and printer. The I / O devices and interfaces can include one or more display devices, such as a monitor, that allows the visual presentation of data to a user. More particularly, a display device provides for the presentation of GUIs as application software data, and multi-media presentations, for example. The I / O devices and interfaces can also provide a communications interface to various external devices. The computer system can include one or more multi-media devices, such as speakers, video cards, graphics accelerators, and microphones, for example.

[0200] The computer system can run on a variety of computing devices, such as a server, a Windows server, a Structure Query Language server, a Unix Server, a personal computer, a laptop computer, and so forth. In other embodiments, the computer system may runon a cluster computer system, a mainframe computer system and / or other computing system suitable for controlling and / or communicating with large databases, performing high volume transaction processing, and generating reports from large databases. The computing system can be generally controlled and coordinated by an operating system software, such as Windows XP, Windows Vista, Windows 7, Windows 8, Windows 10, Windows 11, Windows Server, Unix, Linux (and its variants such as Debian, Linux Mint, Fedora, and Red Hat), SunOS, Solaris, Blackberry OS, z / OS, iOS, macOS, or other operating systems, including proprietary operating systems. Operating systems control and schedule computer processes for execution, perform memory management, provide file system, networking, and I / O services, and provide a user interface, such as a graphical user interface (GUI), among other things.

[0201] The computer system can be coupled to a network, such as a LAN, WAN, or the Internet via a communication link (wired, wireless, or a combination thereof). The network can communicate with various computing devices and / or other electronic devices. The network can communicate with one or more computing systems and one or more data sources. The module can access or may be accessed by computing systems and / or data sources through a web-enabled user access point. Connections may be a direct physical connection, a virtual connection, and other connection type. The web-enabled user access point may comprise a browser module that uses text, graphics, audio, video, and other media to present data and to allow interaction with data via the network.

[0202] Depending on the embodiment, certain acts, events, or functions of any of the processes or algorithms described herein can be performed in a different sequence, can be added, merged, or left out altogether (for example, not all described operations or events are necessary for the practice of the algorithm). Moreover, in certain embodiments, operations or events can be performed concurrently.

[0203] he various illustrative logical blocks, modular dispensers, routines, and algorithm steps described in connection with the embodiments disclosed herein can be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modular dispensers, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. The describedfunctionality can be implemented in varying ways for each particular application, but such variant decisions should not be interpreted as causing a departure from the scope of the disclosure.

[0204] Moreover, the various illustrative logical blocks and modular dispensers described in connection with the embodiments disclosed herein can be implemented or performed by a machine, such as a general purpose processor device, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor device can be a microprocessor, but in the alternative, the processor device can be a controller, microcontroller, or state machine, combinations of the same, or the like. A processor device can include electrical circuitry configured to process computer-executable instructions. In another embodiment, a processor device includes an FPGA or other programmable device that performs logic operations without processing computer-executable instructions. A processor device can also be implemented as a combination of computing devices, for example, a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Although described herein primarily with respect to digital technology, a processor device may also include primarily analog components. For example, some or all of the signal processing algorithms described herein may be implemented in analog circuitry or mixed analog and digital circuitry. A computing environment can include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable computing device, a device controller, or a computational engine within an appliance, to name a few.

[0205] The elements of a method, process, routine, or algorithm described in connection with the embodiments disclosed herein can be embodied directly in hardware, in a software module executed by a processor device, or in a combination of the two. A software module can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of a non-transitory computer-readable storage medium. An exemplary storage medium can be coupled to the processor device such that the processor device can read information from, and write information to, the storage medium. In the alternative, the storage medium can be integral to the processor device. The processor device and the storage medium can reside in an ASIC. The ASIC can residein a user terminal. In the alternative, the processor device and the storage medium can reside as discrete components in a user terminal.

[0206] It is intended that the scope of this present invention herein disclosed should not be limited by the particular disclosed embodiments described above. This invention is susceptible to various modifications and alternative forms, and specific examples have been shown in the drawings and are herein described in detail. This invention is not limited to the detailed forms or methods disclosed, but rather covers all equivalents, modifications, and alternatives falling within the scope of the various embodiments described and the appended claims. Various features of the orthodontic brackets and archwires described herein can be combined to form further embodiments, which are part of this disclosure.

[0207] Methods of using the orthodontic brackets and / or archwires (including device(s), apparatus(es), assembly(ies), structure(s) or the like) are included herein; the methods of use can include using or assembling any one or more of the features disclosed herein to achieve functions and / or features of the system(s) as discussed in this disclosure. Methods of manufacturing the foregoing system(s) are included; the methods of manufacture can include providing, making, connecting, assembling, and / or installing any one or more of the features of the system(s) disclosed herein to achieve functions and / or features of the system(s) as discussed in this disclosure.

[0208] Various other modifications, adaptations, and alternative designs are of course possible in light of the above teachings. Therefore, it should be understood at this time that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein. It is contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments disclosed above may be made and still fall within one or more of the inventions. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with an embodiment can be used in all other embodiments set forth herein. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above. Moreover, while the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not tobe limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the various embodiments described and the appended claims. Any methods disclosed herein need not be performed in the order recited. The methods disclosed herein include certain actions taken by a practitioner; however, they can also include any third-party instruction of those actions, either expressly or by implication. For example, actions such as “tying a tie onto an orthodontic bracket” includes “instructing the tying of a tie onto an orthodontic bracket.” The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers preceded by a term such as “approximately”, “about”, and “substantially” as used herein include the recited numbers (e.g., about 10% = 10%), and also represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.

Claims

WHAT IS CLAIMED IS:

1. A system for custom shaping an archwire for orthodontic treatment, the system comprising: a robot comprising a tool, the tool configured to move a first connector of the archwire to a position corresponding to a digital marker in a virtual model of a patient’s teeth in a planned alignment such that an interproximal segment between the first connector and a second connector of the archwire is in a custom nonpl anar shape; and a heating device configured to heat set the interproximal segment such that the custom nonplanar shape is a memorized shape of the interproximal segment.

2. The system of Claim 1, further comprising a holder configured to hold the second connector of the archwire.

3. The system of any of the preceding claims, further comprising an actuator configured to advance the archwire to position the first connector for grasping by the tool of the robot.

4. The system of Claim 2, wherein the actuator is configured to advance the archwire to position the second connector of the archwire for holding by the holder.

5. The system of Claim 3, wherein the actuator is configured to advance the archwire to position the second connector of the archwire for grasping by the tool of the robot.

6. The system of Claim 5, wherein the actuator is configured to advance the archwire to position a third connector of the archwire for holding by a holder.

7. The system of Claim 1, wherein the tool is configured to move the second connector of the archwire to a position corresponding to a second digital marker in the virtual model such that a second interproximal segment between the second connector and a third connector of the archwire is in a second custom nonplanar shape, and wherein the heating device is configured to heat set the second interproximal segment such that the second custom nonplanar shape is a memorized shape of the second interproximal segment.

8. A method of custom shaping an archwire, the method comprising: grasping a first connector of an archwire; holding a second connector of the archwire;moving the first connector of the archwire to a position corresponding to a digital marker in a virtual model of a patient’s teeth in a planned alignment such that an interproximal segment between the first connector and a second connector of the archwire is in a custom nonplanar shape; and applying energy to the interproximal segment to set the interproximal segment such that the custom nonplanar shape is a memorized shape of the interproximal segment.

9. The method of Claim 8, further comprising advancing the archwire with an actuator to position the first connector for grasping by a tool of a robot.

10. The method of Claim 8 or 9, further comprising advancing the archwire with an actuator to position the second connector for grasping by a holder.

11. The method of any of Claims 8-10, further comprising: grasping the second connector of the archwire; holding a third connector of the archwire; moving the second connector of the archwire to a position corresponding to a second digital marker in the virtual model of the patient’s teeth in the planned alignment such that a second interproximal segment between the second connector and the third connector of the archwire is in a second custom nonplanar shape; and applying energy to the second interproximal segment to set the second interproximal segment such that the custom nonplanar shape is a memorized shape of the second interproximal segment.

12. A system for custom shaping an archwire for orthodontic treatment, the system comprising: a robot configured to move a first portion of the archwire to a custom nonplanar shape; and a device configured to apply energy to the first portion to set the first portion such that the custom nonplanar shape is a memorized shape of the first portion.

13. The system of Claim 12, further comprising any of the features described in the present application.

14. A method of custom shaping an archwire, the method comprising: grasping a first portion of an archwire;moving the first portion of the archwire to a custom nonplanar shape; and applying energy to the first portion to set the first portion such that the custom nonplanar shape is a memorized shape of the first portion.

15. A method of custom shaping an archwire, the method comprising: grasping a first connector of an archwire; holding a second connector of the archwire, the second connector adjacent to the first connector: moving the first connector to a first digitally planned position relative to the second connector such that a first archwire segment connecting the first and the second connectors is in a first custom nonplanar shape; applying energy to the first archwire segment to set the first archwire segment in the first custom nonplanar shape; grasping the second connector of the archwire; holding a third connector of the arch wire, the third connector adjacent the second connector; moving the second connector to a second digitally planned position relative to the third connector such that a second archwire segment connecting the second and the third connectors is in a second custom nonplanar shape; and applying energy to the second archwire segment to set the second archwire segment in the second custom nonplanar shape.1 . A method of custom shaping an archwire, the method comprising: grasping a first connector of an archwire; holding a second connector of the archwire, the second connector adjacent to the first connector: moving the first connector to a first digitally planned position relative to the second connector such that a first archwire segment connecting the first and the second connectors is in a first custom nonplanar shape; and applying energy to the first archwire segment to set the first archwire segment in the first custom nonplanar shape.

17. The method of Claim 16, wherein grasping the first connector of the archwire comprises grasping the first connector with a gripper of an automated machine.

18. The method of Claim 17, wherein the automated machine is a robot.

19. The method of Claim 15, wherein grasping the first connector of the archwire comprises actuating a gripper to clamp on the first connector.

20. The method of Claim 19, wherein the gripper is an actuatable clamp.

21. The method of any of Claims 16-20, wherein holding the second connector of the archwire comprises actuating a clamp to hold the second connector.

22. A method of custom shaping an archwire, the method comprising: moving a first connector of an archwire to a digitally planned position relative to a second connector of the archwire such that an archwire segment connecting the first and the second connectors is in a custom nonplanar shape; and applying energy to the archwire segment to set the archwire segment in the custom nonplanar shape.

23. A system for custom shaping an archwire for orthodontic treatment, the system comprising: a gripper configured to grasp a first connector of an archwire; a clamp configured to hold a second connector of the archwire, the second connector being adjacent the first connector; and an energy application device; wherein the gripper is configured to move the first connector to a digitally planned position relative to the second connector such that a segment of the archwire connecting the first and the second connectors is in a custom nonplanar shape; and wherein the energy application device is configured to apply energy to the archwire segment to set the archwire segment in the custom nonplanar shape.

24. The system of Claim 23, wherein the energy application device comprises a heat gun, the heat gun configured to apply heat to the archwire segment.

25. The system of Claim 23. wherein the energy application device comprises an electrode, the electrode configured to apply electrical energy to the archwire segment.

26. The system of any of Claims 23-25, wherein the gripper is automated.

27. The system of any of Claims 23-26, wherein the clamp is automated.

28. The system of any of Claims 23-27, further comprising a robot, the robot comprising the gripper.

29. The system of any of Claims 23-28, further comprising a second clamp configured to hold the archwire and deliver the second connector to the clamp.

30. The system of Claim 29, wherein the second clamp is configured to be advanced from a loading location to deliver the second connector to the clamp.

31. The system of Claim 30, wherein the second clamp is configured to be advanced to deliver a third connector, adjacent the second connector, to the clamp after the energy application device applies energy to the archwire segment.

32. The system of Claim 31, wherein the gripper is configured to grasp the second connector after the second clamp delivers the third connector to the clamp.

33. The system of any of Claims 23-32, further comprising a vision system configured to collect visual data regarding the archwire to guide actions by the system.

34. The system of any of Claims 23-33, further comprising athird clamp configured to receive the archwire from an operator during a loading procedure.

35. The system of Claim 34, further comprising a second vision system configured to determine if the archwire is properly received by the third clamp.

36. A system for custom shaping an archwire for orthodontic treatment, the system comprising: an automated gripper configured to grasp a first connector of an archwire; a first automated clamp configured to hold a second connector of the archwire, the second connecting being adjacent the first connector; a second automated clamp configured to support the archwire, the second automated clamp configured to be linearly translated while holding the portion of the archwire to position the archwire to be held by the first automated clamp; an energy application device; wherein the automated gripper is configured to move the first connector to a digitally planned position relati ve to the second connector such that a segment of the archwire connecting the first and the second connectors is in a custom nonplanar shape; and wherein the energy application device is configured to apply energy to the archwire segment to set the archwire segment in the custom nonplanar shape.

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