3D-Printed Orthodontic Aligners with Integrated Divot Anchors
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Solution Overview
Problem
Conventional orthodontic aligner manufacturing methods are time-consuming, costly, and result in inaccurate fittings, discomfort, and unbalanced occlusion forces, limiting the effectiveness of tooth realignment and increasing the risk of TMJ injury.
Innovation Solution
Direct 3D-printed orthodontic aligners with torque, rotation, and full-control anchors, utilizing innovative anchoring designs and materials that allow for precise force application and improved fit, reducing the need for multiple molds and trimming steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoforming processes are used to manufacture aligners, then the aligners can be produced with standard materials, but the manufacturing process becomes time-consuming, costly, and requires multiple molds and trimming steps
Solution Approach 1:
The patent combines the aligner and attachment aperture features into a single integrated component that is directly 3D printed. This eliminates the need for separate molding steps and assembly operations, reducing both manufacturing complexity and treatment time while maintaining the functional requirements of the aligner system
Solution Approach 2:
The invention changes the manufacturing method from conventional thermoforming to direct 3D printing additive manufacturing. This parameter change enables complex geometries including integrated attachment apertures to be produced in a single step, eliminating multiple molds and trimming steps while reducing overall treatment time
2Ease of manufacture
If conventional thermoforming is used to create attachment apertures, then the aligners can be manufactured with simple processes, but the aperture shapes are limited and the aligners may bind with attachments making removal difficult
Solution Approach 1:
The patent changes the manufacturing approach from thermoforming to direct 3D printing, which enables complex aperture geometries including non-planar, three-dimensional shapes that provide optimized engagement with attachments. This improves both ease of installation and removal while maintaining manufacturing efficiency
Solution Approach 2:
The invention transitions from two-dimensional aperture shapes possible with thermoforming to three-dimensional aperture geometries enabled by 3D printing. This dimensional enhancement allows for optimized attachment engagement that facilitates easier installation and removal while maintaining secure fit
3Manufacturing precision
If conventional aligners are trimmed to fit gingival margin, then the aligners can be adapted to patient anatomy, but inaccurate trimming causes sharp flanges, discomfort, and soft tissue inflammation
Solution Approach 1:
The patent changes the manufacturing method from subtractive trimming to additive 3D printing, which enables precise control of the gingival margin geometry. The aligner can be printed with smooth, accurately contoured edges that perfectly adapt to the gingival margin without creating sharp flanges, thereby eliminating soft tissue irritation while maintaining precise fit
Solution Approach 2:
The invention performs the adaptation to gingival margin anatomy during the 3D printing process itself, before the aligner is delivered to the patient. The precise geometry is built in during manufacturing rather than requiring post-manufacturing trimming, preventing soft tissue damage from the outset
4Productivity
If conventional aligners are used, then the treatment can proceed with standard appliances, but unbalanced occlusion forces cause TMJ injury and molar intrusion
Solution Approach 1:
The patent changes the manufacturing method to direct 3D printing, which enables precise control of aligner thickness and material properties. This allows for optimized force distribution across multiple teeth, creating balanced occlusion forces that prevent TMJ injury and molar intrusion while maintaining treatment efficiency
Solution Approach 2:
The invention enables different regions of the aligner to have different material properties and thicknesses through 3D printing. This local quality control allows precise modulation of forces applied to different teeth, ensuring balanced occlusion forces that protect against TMJ injury while maintaining productive tooth movement
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 solution enables more efficient, comfortable, and precise tooth realignment with reduced treatment time and material waste, minimizing discomfort and the risk of TMJ injury by providing better adaptation and fit of aligners to teeth.
Implementation Method 1
The aligner is responsible for moving the teeth toward their final pre-determined or aesthetically/functionally correct position
Data Source
AI summary
Direct 3D-printed orthodontic aligners with torque, rotation, and full-control anchors are provided. In an implementation, an orthodontic system uses 3D-printed aligners to perform orthodontic treatment of teeth. Manufacturing the aligners by 3D-printing or additive manufacturing processes imparts novel geometries to the aligners for applying torque, rotation, and full 3D control forces to the teeth in novel ways. The 3D-printed aligners may contain multiple different plastic or metal materials with different orthodontic properties. In an implementation, divot anchors can be strategically applied to teeth to work in conjunction with a 3D-printed aligner fitted over the divot anchors and teeth. The divot anchors may include a depression, channel, groove, or notch providing an attachment point for the aligner to apply a force to the tooth through the divot anchor, such as a torque, rotational force, leverage, push, pull, or 3D control force.