3D-Printed Palate Expander for Custom Fit and Fewer Adjustments

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Solution Overview

Problem

Existing palate and arch expanders are often uncomfortable due to poor fit, require inconvenient daily or weekly adjustments, and are more time-consuming and costly to manufacture, limiting their accessibility.

Innovation Solution

Customized palate and arch expanders are designed using 3D scan data to create precise, patient-specific appliances. These appliances feature a teeth-engaging portion and a force-generating portion, such as a resilient structure or hydratable polymer, directly manufactured to provide optimal fit and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional palate expanders are used, then palate expansion function is achieved, but fit and comfort are poor

Engineering Contradiction:

Improvefit and comfortVSAvoidcustomization process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

3D scanning and digital modeling are performed in advance to create a precise virtual model of the patient's palate and teeth. This preliminary digital preparation enables the expander to be customized for optimal fit and comfort before manufacturing, resolving the contradiction between improved reliability and increased device complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A digital copy or virtual model of the patient's oral anatomy is created through 3D scanning. This digital replica is then used to design and manufacture the customized expander, allowing precise fitting without requiring complex manual adjustment processes, thus improving comfort while managing complexity.

Inventive Principle:

Principle #26Copying

2Reliability

If traditional palate expanders are used, then palate expansion is achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improveexpansion effectivenessVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Traditional mechanical fabrication methods are replaced with additive manufacturing (3D printing) technology. This substitution enables direct manufacturing of customized expanders from digital models, significantly reducing manufacturing time and cost while maintaining expansion effectiveness, thus resolving the contradiction between reliability and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The manufacturing process parameters are changed from traditional subtractive or assembly-based methods to additive manufacturing parameters. This change allows for efficient production of complex customized geometries that would be time-consuming and costly to manufacture using traditional methods, improving productivity without sacrificing expansion effectiveness.

Inventive Principle:

Principle #35Parameter changes

3Force

If traditional palate expanders are used, then expansion force is applied, but adjustments require frequent patient visits

Engineering Contradiction:

Improveexpansion forceVSAvoidadjustment convenience

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The expander is designed with self-adjusting features that allow patients to control the expansion force themselves without requiring frequent professional adjustments. The device incorporates mechanisms such as adjustable screws or elastic elements that patients can modify at home, improving ease of operation while maintaining effective expansion force.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The expander incorporates dynamic adjustment capabilities that allow the expansion force to be modified over time according to treatment progress. This dynamic design enables patients to adjust the force as needed, eliminating the need for frequent clinic visits and making the operation more convenient while maintaining effective expansion.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The customized expanders improve fit and comfort, enhance treatment compliance, and reduce manufacturing time and costs, making them more accessible to patients.

Implementation Method 1

The force generating portion comprises a hydratable polymer configured to expand when contacting saliva of the patient

Methodology Applied

Scientific EffectHydration: Hydrophile

Implementation Method 2

These appliances feature a teeth-engaging portion and a force-generating portion, such as a resilient structure

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250152307A1Methods for direct fabrication of appliances for palate expansion

Publication Date: 2025.05.15 ALIGN TECHNOLOGY INC

AI summary

Systems, methods, and devices for producing appliances for expansion of the palate of a patient are provided. A palate expanding orthodontic appliance comprises a teeth engagement portion comprising a plurality of teeth engagement structures and a force generating portion coupled to the teeth engagement portion and configured to apply force to cause the patient's palate to expand. The orthodontic appliances can be designed according to the specifications provided herein and manufactured using direct fabrication methods.