3D-Printed Clear Aligners With Post-Curing for High Transparency
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Solution Overview
Problem
Existing transparent dental alignment devices face challenges in achieving high enough transparency levels, particularly those produced using 3D printing techniques, which fail to meet user aesthetic demands due to insufficient post-processing.
Innovation Solution
A manufacturing method involving 3D printing with a composition of photocurable compounds, followed by partial curing, air removal with compressed air, post-curing at specific temperatures, controlled heating rates, and thorough cleaning with alcohol and water, enhances transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If 3D printing technique is used to manufacture transparent dental alignment device, then manufacturing flexibility and customization are improved, but transparency and aesthetic appearance deteriorate
Solution Approach 1:
The manufacturing process is divided into distinct stages: 3D printing to create the basic structure, partial curing to maintain workability, and post-curing to achieve final transparency. This segmentation allows each stage to optimize for its specific purpose without compromising the other requirements.
Solution Approach 2:
The device is partially cured during 3D printing to maintain flexibility for shaping and fitting, then the remaining uncured resin is removed and post-curing is performed to achieve high transparency. This preliminary action allows the material to be shaped before final curing.
2Illumination intensity
If compressed air spraying is used to remove uncured resin, then transparency is improved by removing trapped resin, but manufacturing complexity increases
Solution Approach 1:
Compressed air is used to spray and remove uncured resin from the device surface. This pneumatic method is more effective than manual cleaning and achieves better transparency by thoroughly removing trapped resin without requiring complex equipment.
3Illumination intensity
If post-curing is performed at higher temperature, then transparency and curing completeness are improved, but risk of resin degradation and warping increases
Solution Approach 1:
The post-curing process uses controlled temperature parameters (60-90°C) and time parameters to achieve complete curing and high transparency while preventing resin degradation. This optimized parameter combination ensures both transparency and material stability.
Solution Approach 2:
The curing process continues from partial curing during printing through post-curing to complete curing, maintaining continuous transformation of the resin from uncured to fully cured state. This continuous action ensures complete transparency without interrupting the curing process.
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 method produces dental alignment devices with superior transparency, addressing the aesthetic concerns of users and improving the market appeal of transparent orthodontic devices.
Implementation Method 1
3D printing the dental alignment device using a composition for forming transparent dental alignment devices as the raw material
Implementation Method 2
Removing uncured resin and liquid (e.g., water) from the dental alignment device obtained in step S10 (S20). The step (S20) is performed by spraying compressed air with a pressure of 5-12 bar into the dental alignment device
Implementation Method 3
Post heat treatment of the dental alignment device obtained in step S30 (S40). The step (S40) is performed at a rate of less than or equal to 25°C/min, starting from a temperature of 60-90°C
Data Source
Figure 1~4
AI summary
The present invention discloses a Transparent Dental Alignment Device and a manufacturing method for the Transparent Dental Alignment Device. The disclosed manufacturing method for the Transparent Dental Alignment Device includes the steps: 3D printing the dental alignment device using a composition for forming transparent dental alignment devices as the raw material (S10) Removing uncured resin and liquid from the dental alignment device obtained in step S10 (S20) Post-curing the dental alignment device obtained in step S20 (S30) Post heat treatment of the dental alignment device obtained in step S30 (S40) Cleaning the dental alignment device obtained in step S40 (S50).