Scannable healing abutment and method of manufacture thereof

Abstract

The present disclosure relates to a method of manufacturing a scannable healing abutment, the method comprising: providing a healing abutment configured for placement onto a dental implant, wherein the healing abutment is formed from a polymer, such as polyether ether ketone (PEEK); and laser‑etching or laser-engraving an information marker onto a surface, such as a top or side surface, of the healing abutment, the information marker uniquely identifying the healing abutment. The present disclosure further relates to a scannable healing abutment and the use of the scannable healing abutment.

Description

[0001] P7661 PC00

[0002] Scannable Healing Abutments, Associated Methods of Manufacture and Identification, and Imaging Systems

[0003] The present disclosure relates to the field of digital dentistry and is specifically directed to methods for manufacturing a scannable healing abutment, the scannable healing abutment itself, and the use of the scannable healing abutment.

[0004] Background

[0005] Current state of the art in digital dental implant treatment involves a procedure in which an implant is first inserted into the bone. A healing abutment is then affixed to the implant so that the healing abutment protrudes above the gum. Once the implant is placed and the healing abutment is fixed on top of the implant(or abutment), the healing abutment plays a role in conditioning the surrounding gum tissue to form an emergence profile for the eventual permanent prosthetic tooth. This temporary component not only facilitates the healing of both bone and soft tissue and shapes the gum line prior to permanent insertion of the prosthetic tooth, but also serves as a protective barrier against plaque accumulation during the early stages of digital dental implant treatment.

[0006] However, the healing abutment is only a temporary solution within the complete dental treatment process. After healing has occurred (including both the osseointegration of the implant and the conditioning of the soft tissue around the gingiva) a clinician must eventually replace the healing abutment with the permanent prosthetic tooth. Recent advances in the industry have led to the development of scannable healing abutments that may have information markers, thereby enabling the unique identification of the specific characteristics of each healing abutment while the healing abutment remains in situ. This helps with ensuring the accurate matching of a prosthetic tooth to the implant in the patient's jaw, which is important to ensure that the prosthetic tooth, with the particular size and shape of the prosthetic tooth, matches the contour surrounding the implant in the patient’s mouth and fits into the gap left by the healed gum.

[0007] Conventional methods for encoding healing abutments with information markers rely on mechanical milling or engraving machines, which is a slow and tedious process requiring long fabrication times and high energy consumption, which can lead to variability in marker quality and consistency, thereby complicating the identification of the unique characteristics of each healing abutment. These drawbacks render milled orP7661 PC00

[0008] mechanically engraved healing abutments more expensive to manufacture, contributing to an increased overall cost of dental implant treatment procedures. This inconsistency is particularly problematic because accurate recognition of these unique features is crucial for ensuring that the correct prosthetic tooth is matched to the implant in the patient’s jaw, which, being hidden by the healing abutment, is not directly accessible to a clinician without removal of the healing abutment.

[0009] The present disclosure therefore has the objective to provide a solution that addresses these limitations by enhancing the reliability and consistency of healing abutment identification through improved manufacturing methods, which confers significant benefits in terms of patient recovery from the treatment and comfort.

[0010] Summary

[0011] Considering the prior art described above, a first aspect of the present disclosure provides a method of manufacturing a scannable healing abutment, the method comprising: providing a healing abutment configured for placement onto a dental implant; laser-etching or laser-engraving an information marker onto a surface, such as a top or side surface, of the healing abutment, the information marker uniquely identifying the healing abutment. The present disclosure also extends to healing abutments manufactured according to the presently disclosed methods, the healing abutment preferably comprising: a top surface and / or a side surface for engaging a gingiva.

[0012] This solution enables the consistent and accurate application of information markers that can be detected by an imaging system, such as an intraoral scanner 13D scanner or a standard camera, or visually by a clinician during intraoral inspection, without requiring removal of the healing abutment to access the underlying implant. The laser etching I laser-engraving process achieves high precision while minimising damage to the surrounding material, thus ensuring reliable encoding and subsequent reading of critical implant or healing abutment-related information, as described herein.

[0013] Furthermore, relative to conventional mechanical milling techniques, the laser-etching I laser-engraving method of the present disclosure enables shorter fabrication times and lower energy consumption, thereby reducing the manufacturing cost of healing abutments and, in turn, lowering the overall cost of dental implant treatment procedures for patients and clinicians.P7661 PC00

[0014] The laser-etching I laser engraving creates a structure in the surface of the healing abutment which is significant enough to be picked by on 3D-scanners I intraoral scanners during scanning and be visible and readable on the resulting scans. By doing the information coding with a laser, the laser-based approach makes it possible to provide the etching I engraving in a dimension of the information markers which is small enough to fit a sufficient amount of legible information markers onto the surface of the healing abutment to cover a large range of different coding identifiers. The laserbased approach also enables the use of conventional alfa-numerical characters, which are much more intuitive to the human reader. Prior art information coding employing abrasive and / or cutting options take more time and are substantially more expensive. Laser-etching or laser-engraving information markers according to the presently disclosed approach takes only a couple of seconds, while conventional machining would take minutes using prior art methods.

[0015] In a second aspect of the present disclosure, there is provided a scannable healing abutment, preferably manufactured according to the presently disclosed approach, the healing abutment comprising: a body with a top surface, a side surface for engaging a gingiva, and a bottom surface having a mating surface configured for mating to a dental implant inserted into bone in a jaw of a patient.

[0016] In a third aspect of the present disclosure, there is provided the use of a scannable healing abutment manufactured according to the present disclosure or a scannable healing abutment according to the present disclosure optionally during a digital dentistry treatment procedure, such as a treatment for the replacement of missing teeth.

[0017] In a fourth aspect of the present disclosure, there is provided a method of identifying a laser-etched or laser-engraved scannable healing abutment, the method comprising: capturing an image or scan of a healing abutment, such as using a intraoral scanner, 3D scanner, a camera, or even an X-ray imaging system; detecting a laser-etched or laser-engraved information marker on the healing abutment from the captured image or scan; and decoding the laser-etched or laser-engraved information marker to determine an identifier associated with the healing abutment. Preferably, the method is performed while the healing abutment remains affixed to the implant.P7661 PC00

[0018] In a fifth aspect of the present disclosure, there is provided an imaging system for detecting a laser-etched or laser-engraved scannable healing abutment, the system comprising: a 3D scanner and / or a camera configured to capture an image or scan of a healing abutment; and a processor configured to detect a laser-etched or laser-engraved information marker on the healing abutment and determine an identifier associated with the healing abutment.

[0019] In a sixth aspect of the present disclosure, there is provided a computer-readable storage medium comprising instructions which, when executed by a computer, cause an imaging system, such as an intraoral scanner, to carry out a method of identifying information markers on a healing abutment within the mouth of a patient according to the present disclosure.

[0020] Description of the drawings

[0021] The present disclosure will in the following be described in greater detail with reference to the accompanying drawings. Various implementations are described hereinafter with reference to the drawings. The drawings are examples of implementations and are intended to illustrate some of the features of the presently disclosed solution, and are not limiting to the presently disclosed device and method.

[0022] Fig. 1 (a)-(c) are schematic CAD representations of a healing abutment according to the present disclosure.

[0023] Fig. 2 is a schematic CAD representation of the healing abutment in Fig. 1 with a retention screw inserted and secured by a hex nut.

[0024] Fig. 3 is a schematic view of an acronym encoding system using the Latin alphabet according to the present disclosure.

[0025] Fig. 4(a)-(c) is an image of a healing abutment according to the present disclosure, showing the laser-etching output with the acronym-based information marker etched on the top of the body of the healing abutment.P7661 PC00

[0026] Fig. 5 are scans of different healing abutments according to the present disclosure, each healing abutment having a different acronym laser- etched onto the respective top surface of each healing abutment.

[0027] Detailed description of the disclosure

[0028] The term "digital dentistry treatment procedure" as used herein may refer to any dental treatment workflow that incorporates digital technologies for planning dental treatments, such as the replacement of missing teeth. For example, a digital dentistry procedure can include the use of intraoral scans of scannable healing abutments.

[0029] The term "information marker" as used herein may refer to a machine or human readable feature that is incorporated on a healing abutment. The information marker is designed to encode specific data regarding the healing abutment or an implant on top of which the healing abutment is to be placed, including details such as implant type, implant size and / or shape, implant manufacturer, and any other clinically relevant parameters that would aid in the successful completion of the digital dentistry treatment.

[0030] The applied information markers are preferably readable by an intraoral scanner. Examples of intraoral scanners are the iTero Element Series by Align Technology, for example iTero Element 2, Element 5D, Element Flex, the TRIOS Series by 3Shape, for example TRIOS 3, TRIOS 4, TRIOS 5 Wireless, the Medit i700 I i6001 i500 by Medit, Primescan by Dentsply Sirona, and Carestream CS 3700 I CS 3800 by Carestream Dental.

[0031] The following sets out preferred and / or optional features of the first aspect of the present disclosure. Unless stated otherwise, any of the preferred and / or optional features described herein may be combined in any technically feasible manner with one another, and with any preferred and / or optional feature of any other aspect of the present disclosure.

[0032] In some implementations of the present disclosure, the step of providing the healing abutment comprises providing a healing abutment formed from a polymer, preferably a biocompatible polymer and / or a medical device polymer compliant with ISO 10993. Examples of suitable polymers include polyether ether ketone (PEEK), VESTAKEEPP7661 PC00

[0033] (including all variations thereof), polyoxymethylene (POM), polylactic acid (PLA), poly(lactic-co-glycolic acid) (PLGA), polycaprolactone (PCL), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), silicone, polytetrafluoroethylene (PTFE), polycarbonate (PC), and thermoplastic polyurethane (TPU). Among these, PLA, PLGA and PCL are biodegradable polymers. Advantageously, polymers are more readily and easily etched or engraved with a laser than metals, such as titanium. The lower reflectivity of polymers also minimises scattering and reflection of the laser beam. Consequently, the laser-etching or laser-engraving process produces information markers with enhanced precision and reliability, ensuring that the encoded data is accurately and consistently read during digital imaging.

[0034] PEEK, in particular, also offers high biocompatibility, durability, and is metal-free, thus making PEEK particularly advantageous for patients with metal allergies, such as those allergic to titanium. Furthermore, PEEK can be produced in natural colours to match teeth or gingiva, thereby enhancing aesthetic integration and patient comfort when compared with healing abutments made from metals.

[0035] In some implementations of the present disclosure, the healing abutment is made from a composite material comprising a polymer as described herein, for example PEEK or another biocompatible polymer. In such implementations, the polymer preferably constitutes a major proportion by weight of the healing abutment. For example, the polymer may constitute at least 30% by weight, preferably at least 50% by weight, more preferably at least 60% by weight, and most preferably at least 70% by weight of the healing abutment. In some implementations, the polymer constitutes from 30% to 99% by weight, preferably from 50% to 95% by weight, more preferably from 60% to 90% by weight of the healing abutment.

[0036] In some implementations of the present disclosure, the method step of providing a healing abutment may comprise providing a healing abutment in a non-sintered state. Such non-sintered starting material may comprise metal injection moulded (MIM) and ceramic injection moulded (CIM) materials, as well as 3D-printed variations thereof, in which ceramic or metallic powders are bonded via a polymer bonding agent. In such non-sintered starting materials, the polymer bonding agent may constitute from about 20% to about 60% by volume of the feedstock, preferably from about 30% to about 50% by volume of the feedstock. The step of laser-etching or laser-engraving theP7661 PC00

[0037] information marker may be performed on the non-sintered starting material prior to sintering. Laser-etching or laser-engraving the information marker onto non-sintered starting material before sintering may be advantageous because the polymer bonding agent present in the green state material is amenable to laser etching or laserengraving in a manner similar to other polymer materials described herein.

[0038] Alternatively, in some implementations of the present disclosure, the step of providing the healing abutment comprises providing a healing abutment formed from a metal, such as titanium, a metal alloy, such as titanium alloy, and / or a ceramic material. Additionally, in some implementations, the laser etching or laser engraving of the information marker is performed in the polymer of the healing abutment. The laser-etching or laser-engraving may, however, also be performed in the metal, for example where the healing abutment is a composite made from both a polymer and a metal, or where the healing abutment is formed entirely from a metal material.

[0039] Titanium, in particular, and titanium alloys are widely used in dental implants due to their excellent durability and mechanical strength. As for ceramics, these offer an aesthetic appearance for the patient.

[0040] In some implementations of the present disclosure, the step of providing the healing abutment may comprise the step of fixing the healing abutment onto an abutment. In such implementations, the step of laser-etching or laser-engraving the information marker is preferably performed with the healing abutment fixed onto the abutment.

[0041] In some implementations of the present disclosure, the healing abutment is opaque to X-rays, preferably such that in the step of laser-etching or laser-engraving the healing abutment is visible on an X-ray image acquired of the corresponding jaw. This ensures that clinicians can observe the healing abutment and, possibly also its etched or engraved information marker, on an X-ray image.

[0042] Alternatively, when the healing abutment is to be used with a scanner other than an X-ray scanner, it is advantageous to select a material for the healing abutment that ensures visibility in the image outputted by that particular scanner. For example, if an intraoral optical scanner is employed, a material with a high-contrast finish or colour may be selected to ensure the accurate and reliable detection of the information marker in the captured image.P7661 PC00

[0043] In some implementations, the polymer from which the healing abutment is formed may comprise an additive configured to render the healing abutment opaque to a particular form of electromagnetic radiation. For example, the additive may render the polymer opaque to X-rays, visible light, infrared radiation, or any other wavelength range employed by a given scanner or imaging system. The selection of the additive preferably depends on the type of scanner with which the healing abutment is intended to be used, such that the healing abutment provides sufficient contrast in the resulting image or scan to enable reliable detection of the information marker.

[0044] In the step of laser-etching or laser-engraving the information marker, laser etching or engraving is a process that uses a laser beam to mark or engrave the surface of a material. Laser etching or engraving typically works by having a laser beam heating the surface of the material rapidly and is therefore a very fast process. The heat causes the material to melt, expand, or vaporize, creating a permanent mark without cutting deeply into the surface. Laser etching is usually a very shallow process etching to depths of around 25 microns. Laser etching is usually provided by means of CO2lasers, fiber lasers, or diode lasers, depending on the material. In principle laser engraving could be used as well in the presently disclosed approach, because the resulting information markers would also be visible. But laser engraving typically vaporizes material to carver deeper into the surface (compared to laser etching), typically to depths or more than 100 microns, and the laser engraving process is therefore typically slower than laseretching.

[0045] In some implementations of the present disclosure, in the step of laser-etching or laserengraving the information marker, the power setting of the laser is preferably adjusted based on the material used to form the healing abutment, particularly the part of the healing abutment that is to be laser-etched or laser-engraved and will comprise the information marker, to ensure optimal etching or engraving quality without damaging the abutment. For example, polymers typically require lower laser power than metals to achieve the same, precise, high-quality etching or engraving.

[0046] In some implementations of the present disclosure, in the step of laser-etching or laserengraving the information marker, the information marker comprises any combination of one or more of the following: letters, numbers, symbols, or a machine readableP7661 PC00

[0047] marker such as a QR code or barcode. Various methods may be employed to store the unique information associated with the healing abutment and / or the implant on which the healing abutment is to be placed within the information marker. The only requirement is that the marker incorporates features that uniquely identify the stored data, thereby enabling either a clinician or a computer program to retrieve the corresponding information from a database or library mapping the markers to their associated details.

[0048] In some implementations of the present disclosure, in the step of laser-etching or laserengraving the information marker, the information marker comprises a three-letter, four-letter, five-letter, six-letter, or more than six-letter acronym encoding healing abutment or other implant-related information, or information associated with another implant, preferably the implant on which the healing abutment is to be placed. The number of letters may be selected based on the complexity of the information to be stored. For example, if the marker is intended to encode only the height and width of the healing abutment, a two-letter acronym might suffice if the range of variations can be represented within the 26-letter Latin alphabet. However, for more complex data sets (such as those incorporating multiple parameters including implant type, orientation, and manufacturer, etc.) a longer acronym would be required to uniquely represent the necessary information.

[0049] In some implementations of the present disclosure, the step of laser-etching or laserengraving the information marker is performed such that the information marker is detectable by an imaging system, such as an intraoral scanner, a 3D scanner or a camera. In practice, this may mean selecting specific parameters, such as the line widths of etched or engraved lines and the size of the characters, based on the known resolution of an imaging system (for example, an intraoral scanner, a 3D scanner or a camera). By matching the etched or engraved dimensions to the scanner’s resolution, the marker will be easily identified in any captured image.

[0050] In some implementations of the present disclosure, the step of laser etching or laser engraving the information marker is performed using a laser power of at least 20 W, preferably at least 50 W, more preferably at least 75 W, such as at least 95 W, or at least 100 W. Alternatively or additionally, the laser power may be at most 500 W, such as at most 400 W, such as at most 300 W, such as at most 200 W. In someP7661 PC00

[0051] implementations, the laser power is in the range of from 20 W to 500 W, such as from 50 W to 300 W, from 75 W to 200 W, or from 95 W to 150 W. A higher power setting facilitates greater penetration depth of the etching or engraving process, which enhances the marker’s visibility for both manual clinical inspection and automated detection by imaging systems. Alternatively, a higher power setting may facilitate a higher production speed and thus lower costs of manufacture. Conversely, a lower laser power may enable more sharp edges of the etched or engraved features, especially when combined with more than one pass to complete an etching or engraving. Using multiple passes at a lower power setting may thus improve the readability of the information marker.

[0052] In some implementations of the present disclosure, the step of laser etching or laser engraving the information marker is performed with a scan speed, such as a laser raster scanning speed, of at least 100 mm / s, preferably at least 250 mm / s, more preferably at least 500 mm / s, most preferably least 750 mm / s. Advantageously, using a higher scan speed significantly reduces the etching or engraving time per unit, thereby increasing manufacturing throughput.

[0053] In some implementations, in the step of laser-etching or laser engraving the information marker, the laser power and the scan speed are selected to achieve a predetermined etch or engraving depth in the healing abutment.

[0054] In some implementations, the step of laser-etching or laser engraving the information marker is performed with a pulse duration of at least 10 ms, such as at least 25 ms, such as at least 40 ms, or at least 50 ms. A longer pulse duration may help to remove more material per pass of a laser, enabling the desired etch or engraving depth to be reached in fewer passes.

[0055] In some implementations, the step of laser-etching or laser-engraving the information marker comprises performing multiple laser passes over the surface of the healing abutment to achieve a predetermined etch or engraving depth. Preferably, the number of laser passes is at least 4, such as at least 6, such as at least 7, or at least 10.

[0056] Performing multiple passes, rather than a single pass, to achieve the desired depth can advantageously produce information markers with sharp, well-defined edges, thereby improving the readability of the information marker by a suitable imaging system.P7661 PC00

[0057] In some implementations, in the step of laser-etching or laser engraving the information marker, the healing abutment is held in a fixture. Secure fixturing of the healing abutment ensures positional accuracy and repeatability of the laser-etching or laserengraving across successive passes, thereby contributing to the quality and sharpness of the etched or engraved information marker. In some implementations, the fixture is configured to hold a plurality of healing abutments simultaneously, thereby enabling batch processing of multiple healing abutments in a single laser-etching or laser engraving session. Preferably, the method comprises providing at least two such fixtures, wherein one fixture is loaded or unloaded with healing abutments while another fixture holding healing abutments is being processed by the laser.

[0058] In some implementations of the present disclosure, the step of laser etching or engraving the information marker is performed such that the character height of the laser etched or laser engraved information marker is at least 0.2 mm, such as at least 0.4 mm, such as at least 0.6 mm, or at least 0.8 mm. Increasing the character height may increase the ability of either a human clinician or a specifically configured imaging system to accurately identify the characters on a particular healing abutment.

[0059] In some implementations of the present disclosure, in the step of laser-etching or laser engraving the information marker, the information marker encodes at least one parameter selected from: implant type, implant size, implant manufacturer, healing abutment height, healing abutment diameter, healing abutment orientation, implant orientation and position with respect to other structural features, such as a gum line or tooth structure(s) within the patient’s jaw and / or mouth, and patient specific information. The markers according to the present disclosure can therefore convey a comprehensive set of data related to the healing abutment and the implant associated with the healing abutment. The marker may include information critical for ensuring accurate prosthetic matching and overall digital dentistry treatment planning.

[0060] In some implementations of the present disclosure, the step of laser-etching or laser engraving the information marker is performed on a conveyor belt. Preferably, the conveyor belt is moving while the laser etches or engraves the information marker onto the healing abutment. More preferably, the conveyor belt is moving at a speed of at least 0.5 m / min, such as at least 1 m / min, such as at least 2 m / min, or at least 5 m / min.P7661 PC00

[0061] Performing the laser-etching or laser engraving on a moving conveyor belt advantageously enables continuous, high-throughput production of scannable healing abutments, thereby reducing manufacturing time and cost per unit.

[0062] Alternatively or additionally, in some implementations of the present disclosure, the step of laser-etching or laser engraving the information marker is performed using a robotic system for automated handling of the healing abutments. The robotic system may, for example, load and unload healing abutments into fixtures or onto a conveyor belt.

[0063] The following sets out preferred and / or optional features of the second aspect of the present disclosure. Unless stated otherwise, any of the preferred and / or optional features described herein may be combined in any technically feasible manner with one another, and with any preferred and / or optional feature of any other aspect of the present disclosure.

[0064] In some implementations of the scannable healing abutment according to the second aspect, the body of the healing abutment is made of a polymer, such as polyether ether ketone (PEEK). Preferably, an information marker uniquely identifying the healing abutment is etched or engraved onto a surface, such as a top or side surface, of the body of the healing abutment. In other implementations, the information marker is etched or engraved on a side surface of the healing abutment. When the marker is placed on the top surface, the marker is optimally located to avoid obstruction by soft tissue or adjacent structures such as teeth, thus ensuring easier readability during imaging and clinical inspection.

[0065] In some implementations of the scannable healing abutment according to the second aspect, the information marker comprises a three-letter, four-letter, five-letter, six-letter, or more than six-letter acronym encoding healing abutment or other implant-related information, or information associated with another implant.

[0066] In some implementations of the scannable healing abutment according to the second aspect, the healing abutment is made of a metal alloy, such as titanium, or an opaque polymer. An advantage of using a metal alloy, especially titanium alloy, is the increasedP7661 PC00

[0067] durability of titanium alloy, which allows the healing abutment to be reused rather than being a single-use component, which helps to reduce wastage.

[0068] In some implementations of the scannable healing abutment according to the second aspect, the laser etched or laser engraved information marker has a line width of at least 0.15 mm, such as at least 0.20 mm, such as at least 0.25 mm, such as at least 0.3 mm, such as at least 0.4 mm, or at least 0.5 mm. This implementation ensures that the marker has sufficient line width to be reliably detected and decoded, for example, by an imaging system that has a machine-learning algorithm trained for decoding information markers on healing abutments in scanned images.

[0069] In some implementations of the scannable healing abutment according to the second aspect, the body of the healing abutment is formed from a polymer, preferably a biocompatible polymer and / or a medical device polymer compliant with ISO 10993. Examples of suitable polymers include polyether ether ketone (PEEK), VESTAKEEP (including all variations thereof), polyoxymethylene (POM), polylactic acid (PLA), poly(lactic-co-glycolic acid) (PLGA), polycaprolactone (PCL), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), silicone, polytetrafluoroethylene (PTFE), polycarbonate (PC), and thermoplastic polyurethane (TPU). Among these, PLA, PLGA and PCL are biodegradable polymers. Advantageously, polymers are more readily and easily etched or engraved with a laser than metals, such as titanium. The lower reflectivity of polymers also minimises scattering and reflection of the laser beam. Consequently, the laser etching or laser engraving process produces information markers with enhanced precision and reliability, ensuring that the encoded data is accurately and consistently read during digital imaging. PEEK, in particular, also offers high biocompatibility, durability, and is metal-free, thus making PEEK particularly advantageous for patients with metal allergies, such as those allergic to titanium.

[0070] Furthermore, PEEK can be produced in natural colours to match teeth or gingiva, thereby enhancing aesthetic integration and patient comfort when compared with healing abutments made from metals.

[0071] In some implementations of the scannable healing abutment according to the second aspect, the body of the healing abutment may comprise a non-sintered starting material such as metal injection moulded (MIM) or ceramic injection moulded (CIM) materials, as well as 3D-printed variations thereof, in which ceramic or metallic powders areP7661 PC00

[0072] bonded via a polymer bonding agent. In such non-sintered starting materials, the polymer bonding agent may constitute from about 20% to about 60% by volume of the feedstock, preferably from about 30% to about 50% by volume of the feedstock. The information marker may be laser-etched or laser-engraved onto the non-sintered starting material prior to sintering. Laser-etching or laser-engraving the information marker onto non-sintered starting material before sintering may be advantageous because the polymer bonding agent present in the green state material is amenable to laser etching or engraving in a manner similar to other polymer materials described herein.

[0073] Alternatively, in some implementations of the scannable healing abutment according to the second aspect, the body of the healing abutment is formed from a metal, such as titanium, a metal alloy, such as titanium alloy, and / or a ceramic material. Titanium, in particular, and titanium alloys are widely used in dental implants due to their excellent durability and mechanical strength. Ceramics offer an aesthetic appearance for the patient.

[0074] The following sets out preferred and / or optional features of the fourth aspect of the present disclosure. Unless stated otherwise, any of the preferred and / or optional features described herein may be combined in any technically feasible manner with one another, and with any preferred and / or optional feature of any other aspect of the present disclosure.

[0075] In some implementations, the step of decoding the information marker comprises reading the information marker, for example using an optical character recognition (OCR) image scanning software, and creating a digital representation of the information marker, for example, text comprising letters and / or numbers representing the information marker. The digital representation of the information marker may then be identified in a digital look-up table, which may be stored locally or remotely, for example in the cloud, to retrieve information associated with the healing abutment.

[0076] In some implementations of the method according to the fourth aspect, in the step of identifying the information marker from the imaging data, the imaging system, such as an intraoral scanner, further comprises a computer program having instructions which,P7661 PC00

[0077] when executed by a computer, cause the computer to carry out the identification of information markers on a healing abutment within the mouth of a patient.

[0078] The following sets out preferred and / or optional features of the fifth aspect of the present disclosure. Unless stated otherwise, any of the preferred and / or optional features described herein may be combined in any technically feasible manner with one another, and with any preferred and / or optional feature of any other aspect of the present disclosure.

[0079] In some implementations of the imaging system according to the fifth aspect, the imaging system further comprises a computer program having instructions which, when executed, identify and decode the information marker from the captured image or scan.

[0080] Examples

[0081] Figs. 1 (a)-1 (c) show different views of a healing abutment according to the present disclosure. Fig. 1(a) shows a perspective view of a healing abutment 100 from above, illustrating the top surface 102 of the healing abutment 100. An information marker 108, in this example a laser-etched acronym, is positioned on the top surface 102 to uniquely identify the healing abutment. The top surface further includes a notch 110, which is not an essential feature of the healing abutment, which may assist a clinician with positioning or rotational alignment of the healing abutment within the mouth of a patient, and an opening 112 that leads to an internal cavity (not shown in Fig. 1 (a)) extending through the abutment to the bottom surface of the healing abutment, providing access for a retention screw used to secure the healing abutment to a dental implant. In alternative examples according to the present disclosure, the retention screw may be provided as an integral part of the healing abutment, in which case there is no need for an internal cavity.

[0082] Fig. 1(b) depicts another perspective view of the healing abutment 100 depicted in Fig.

[0083] 1 (a), showing both the top surface 102 and the side surface 104 of the healing abutment 100.

[0084] Fig. 1 (c) shows the same angled perspective view of the healing abutment 100 as in Figs. 1 (a) and 1 (b), but with a cut-out of the body of the healing abutment revealing the internal cavity of the healing abutment. The cut-away illustrates how the opening 112 inP7661 PC00

[0085] the top surface 102 connects to the internal cavity, which extends through the body of the healing abutment to the bottom surface of the healing abutment. This cavity is configured for receiving a retention screw for securing the healing abutment to a dental implant. To connect the healing abutment to the implant inserted inside the patient’s bone, the retention screw must be inserted through the opening 112, pass through the internal cavity, and exit through the bottom surface of the healing abutment, where it is threaded into a screw opening located on the occlusal surface of the implant (not shown).

[0086] Figs. 2(a)-2(c) show side perspective views of a healing abutment 200 according to the present disclosure. The top surface 202, side surface 204, and bottom surface 206 of the healing abutment are visible. As previously shown in Figure 1(a), an information marker 208 is laser-etched on the top surface 202 of the body of the healing abutment 200 to uniquely identify the component. A notch 210 is also present on the top surface 202, as in all three Figures 1(a)-1(c). While not essential, this feature provides an orientation reference that can assist the clinician during placement by indicating how the healing abutment is aligned when affixed to a dental implant inside the patient’s mouth.

[0087] A retention screw 214 is inserted through the internal cavity of the healing abutment in all of Figs 2(a)-2(c), with the top portion of the screw protruding through the opening in the top surface (see Figs. 2(a) and 2(c)) and the threaded bottom portion extending out of the bottom surface 206 (visible in all three Figs.). A hex nut 218 is also shown in each figure, positioned around the retention screw to provide an interface for tightening or securing the screw into the implant. In the illustrated implementation, the hex nut 218 is formed integrally with the healing abutment, but in alternative implementations according to the present disclosure, the hex nut may be a separate component.

[0088] Fig. 3 illustrates a schematic view of an acronym encoding system using the Latin alphabet, as applied to the laser-etched information markers described in the present disclosure. The illustrated information marker 308 comprises a multi-character code that is laser-etched onto the top surface of a healing abutment.

[0089] In this illustrated example, the code includes a three-letter acronym used to identify the specific implant onto which the healing abutment is to be placed. A fourth character,P7661 PC00

[0090] represented by a single letter, is used to indicate the height of the healing abutment, while a fifth character, also a single letter, represents the diameter of the healing abutment. This five-character encoding system enables the clinician or a digital imaging system to retrieve relevant implant and abutment specifications with a single scan or visual inspection.

[0091] In other implementations, the acronym may consist of fewer than the number of characters shown where the encoded information is not as complex. Conversely, in more complex cases, the acronym may extend to six or more characters to encode additional parameters.

[0092] The encoding system shown in Fig. 3 supports both human readability (e.g., by the clinician during inspection) and machine readability (e.g., by an imaging system such as an intraoral scanner), ensuring that the correct healing abutment can be identified and matched based on the encoded identifier. In alternative implementations, other encoding formats may be used, particularly in cases where the degrees of freedom in the data to be encoded exceed what can be efficiently represented using acronyms. For example, a laser-etched or laser-engraved machine-readable QR code or barcode may be employed to store more complex or higher-density data, allowing for automatic decoding by imaging systems.

[0093] Figs. 4(a)-(c) show three example images / scans of the same healing abutment 400 according to the present disclosure, each depicting the same healing abutment model (specifically, an Astratech EV 4.2), with Fig. 4(a) being an image captured by a camera and Figs. 4(b) and 4(c) being intraoral scans captured by intraoral scanning devices. An information marker 408 is laser-etched onto the top surface, encoding a unique identifier for that specific model.

[0094] Owing to the selected line width and character size, the five-letter acronym forming the information marker is easily visible in the scans. This visibility ensures that the acronym can be automatically detected and decoded by an imaging system, for example using a machine learning algorithm trained to recognise characters in a scan and output the associated encoded information. Alternatively, the clinician may manually read the acronym in the scan and look up the acronym in a corresponding reference library or database to retrieve the associated implant and / or abutment data.P7661 PC00

[0095] Figs. 5(a)-(e) show separate scans 520 of different healing abutments 500a-e according to the present disclosure, each having a distinct acronym / information marker 524a-e laser-etched onto the top surface of each healing abutment, thereby encoding data associated with and uniquely identifying each healing abutment.

[0096] The healing abutments in Figs. 4 and 5 are laser-etched using a Panasonic LP-RF200P, which is a FAYb Laser marker LP-RF employing a Yb fiber laser, a Class4 laser having a wavelength of 1064 nm.

[0097] The inventors have found that making the healing abutments from VESTAKEEP® PEEK provided by Evonik offers particular advantages. Any of the healing abutments shown in the Figs, or described in the present disclosure may be made (either partly or fully) from this high-performance polymer, which is specifically formulated for dental applications. VESTAKEEP® PEEK includes all variations of the material formulation offered by Evonik, and any such variation may be used. VESTAKEEP® PEEK provides excellent biocompatibility and bone-like elasticity. Being metal-free, it can benefit patients with metal sensitivities, while the low thermal conductivity of VESTAKEEP® PEEK, ease of laser etching or laser-engraving, and durability make it an ideal material for manufacturing healing abutments according to the present disclosure. However, any biocompatible polymer material conferring these benefits may be used instead.

[0098] The systems and methods described herein may comprise or be implemented by a computer program or a plurality of computer programs, which may exist in a variety of forms both active and inactive in a single computer system or across multiple computer systems. For example, they may exist as software program(s) comprised of program instructions in source code, object code, executable code or other formats for performing some of the steps. Any of the above may be embodied on a computer readable medium, which include storage devices and signals, in compressed or uncompressed form.

[0099] The term "computer" refers to any electronic device comprising a processor, such as a general-purpose central processing unit (CPU), a specific purpose processor or a microcontroller. A computer is capable of receiving data (an input), of performing a sequence of predetermined operations thereupon, and of producing thereby a result inP7661 PC00

[0100] the form of information or signals (an output). Depending on context, the term "computer" will mean either a processor in particular or can refer more generally to a processor in association with an assemblage of interrelated elements contained within a single case or housing.

[0101] As used herein, a “computer-readable medium” or “storage medium” can be any means that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium can be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium can include the following: an electrical connection having one or more wires, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fibre, and a portable compact disc read-only memory (CDROM).

[0102] Further details of drawings

[0103] 100, 200, 400, 500a-e - healing abutment

[0104] 102, 202 - top surface of healing abutment

[0105] 104, 204 - side surface of healing abutment

[0106] 106, 206 - bottom surface of healing abutment

[0107] 108, 208, 308, 408 - information marker

[0108] 110, 210 - notch on top surface of healing abutment

[0109] 112, 212 - opening in the top surface of healing abutment

[0110] 214 - retention screw

[0111] 216 - thread of the retention screw

[0112] 218 - hex nut

[0113] 420, 520 - imaging scan

[0114] 422, 522a-e - information marker acronym

Claims

P7661 PC00Claims1. A method of manufacturing a scannable healing abutment, wherein the method comprises the steps of:(a) providing a healing abutment configured for placement onto a dental implant, wherein the healing abutment is formed from a polymer; and(b) laser-etching or laser-engraving an information marker onto a surface, such as a top or side surface, of the healing abutment, the information marker uniquely identifying the healing abutment.

2. The method according to claim 1 , wherein the polymer comprises one or more of: polyether ether ketone (PEEK), polyoxymethylene (POM), polylactic acid (PLA), poly(lactic-co-glycolic acid) (PLGA), polycaprolactone (PCL), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), silicone, polytetrafluoroethylene (PTFE), polycarbonate (PC), and thermoplastic polyurethane (TPU).

3. The method according to claim 1 or claim 2, wherein in step (a) the healing abutment is further formed from a metal, such as titanium, a metal alloy, such as titanium alloy, and / or a ceramic material, and wherein in step (b) the laser-etching or laser-engraving of the information marker is performed in the polymer of the healing abutment.

4. The method according to any one of claims 1 to 3, wherein the healing abutment is opaque to X-rays, preferably such that the healing abutment is visible on an X-ray image.

5. The method according to any one of claims 1 to 4, wherein the laser etched or laser-engraved information marker is readable by an intraoral scanner.

6. The method according to any one of claims 1 to 5, wherein the laser etched or laser-engraved information marker comprises any combination of one or more of the following: letters, numbers, symbols, or a machine readable marker such as a QR code or barcode.P7661 PC007. The method according to any one of claims 1 to 6, wherein the laser-etched or laser-engraved information marker comprises a three-letter, four-letter, five-letter, six-letter, or more than six-letter acronym encoding healing abutment or other implant-related information, or information associated with another implant, preferably an implant on top of which the healing abutment is to be placed.

8. The method according to any one of claims 1 to 7, wherein in step (b) the laser-etching or laser-engraving is performed such that the information marker is detectable by an imaging system, such as a 3D scanner or a camera.

9. The method according to claim 8, wherein in step (b) a line width and / or character size is / are selected based on a resolution of an imaging system.

10. The method according to any one of claims 1 to 9, wherein in step (b) the laser-etching or laser-engraving is performed using a laser power in the range of from 20 W to 500 W, such as from 50 W to 300 W, from 75 W to 200 W, or from 95 W to 150 W.

11. The method according to any one of claims 1 to 10, wherein in step (b) the laser-etching or laser-engraving is performed with a scan speed, such as a laser raster scanning speed, of at least 100 mm / s, such as at least 250 mm / s, such as at least 500 mm / s, or at least 750 mm / s.

12. The method according to any one of claims 1 to 11 , wherein the laser power and the scan speed, such as a laser raster scanning speed, are selected to achieve a predetermined etch depth in the healing abutment.

13. The method according to any one of claims 1 to 12, wherein in step (b) the laser-etching or laser-engraving is performed such that the character height of the laser-etched or laser-engraved information marker is at least 0.2 mm, such as at least 0.4 mm, such as at least 0.6 mm, or at least 0.8 mm.

14. The method according to any one of claims 1 to 13, wherein the laser-etched or laser-engraved information marker encodes at least one parameter selectedP7661 PC00from: implant type, implant size, implant manufacturer, healing abutment height, healing abutment diameter, healing abutment orientation, implant orientation and position with respect to other structural features, such as a gum line or tooth structure(s) within the patient’s jaw and / or mouth, and patient-specific information.

15. The method according to any one of claims 1 to 14, wherein in step (a) the healing abutment is provided in a non-sintered state, and wherein in step (b) the laser-etching or laser-engraving of the information marker is performed on the non-sintered starting material prior to sintering.

16. The method according to claim 15, wherein the non-sintered starting material comprises metal injection moulded (MIM) material or ceramic injection moulded (CIM) material.

17. The method according to claim 16, wherein the ceramic or metallic powders of ceramic injection moulded (CIM) material or the metal injection moulded (MIM) material are bonded via a polymer bonding agent, and wherein the polymer bonding agent constitutes from about 20% to about 60% by volume of the feedstock.

18. The method according to any one of claims 1 to 17, wherein in step (b) the laser-etching or laser-engraving of the information marker is performed on a conveyor belt.

19. The method according to claim 18, wherein the conveyor belt is moving while the laser etches or engraves the information marker onto the healing abutment.

20. The method according to claim 18 or claim 19, wherein a robotic system is used for automated handling of the healing abutments, the robotic system being configured to load and unload the healing abutments onto the conveyor belt.

21. A scannable healing abutment, preferably manufactured according to any one of claims 1 to 20, the healing abutment comprising:(i) a body with a top surface, a side surface for engaging a gingiva; andP7661 PC00(ii) a bottom surface having a mating surface configured for mating to a dental implant inserted into bone in a jaw of a patient.

22. The healing abutment according to claim 21 , wherein the body of the healing abutment is made of a polymer, such as polyether ether ketone (PEEK).

23. The healing abutment according to claim 21 or claim 22, wherein an information marker uniquely identifying the healing abutment is etched onto a surface, such as a top or side surface, of the body of the healing abutment.

24. The healing abutment according to claim 23, wherein the information marker comprises a three-letter, four-letter, five-letter, six-letter, or more than six-letter acronym encoding healing abutment or other implant-related information, or information associated with another implant.

25. The healing abutment according to any of claims 21 to 24, wherein the body of the healing abutment is made of a metal, such as titanium, a metal alloy, such as a titanium alloy, and / or a ceramic material.

26. The healing abutment according to any of claims 21 to 25, wherein the body of the healing abutment is made of a polymer which is opaque to X-rays such that the healing abutment is visible on an X-ray image.

27. The healing abutment according to any of claims 21 to 26, wherein the laser-etched or laser-engraved information marker has a line width of at least 0.15 mm, such as at least 0.20 mm, such as at least 0.25 mm, such as at least 0.3 mm, such as at least 0.4 mm, or at least 0.5 mm.

28. A use of a scannable healing abutment manufactured according to any one of claims 1 to 20 or a scannable healing abutment according to any one of claims 21 to 27 optionally during a digital dentistry treatment procedure, such as a treatment for the replacement of missing teeth.P7661 PC0029. The use according to claim 28, wherein the use comprises digitally scanning the scannable healing abutment using an imaging system and identifying the healing abutment based on the information marker detected in the scan.

30. The use according to claim 28 or claim 29, wherein the use is non-therapeutic.

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