3D-Printed Orthodontic Bracket Assembly for Precise Placement
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Solution Overview
Problem
Traditional orthodontic bracket placement is time-consuming and expensive, often requiring manual handling and prone to human error, while indirect bonding trays necessitate costly equipment and complex processes.
Innovation Solution
A 3D-printed orthodontic bracket system comprising a bracket, placement member, and support member as a single unit, customized for each patient using digital impressions and computer-aided design, allowing simultaneous and precise bracket placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual bracket placement is used, then precision and control are maintained, but chair time and productivity are excessive
Solution Approach 1:
The brackets are pre-positioned on a customizable tray with precise的定位 structures before the bonding procedure. The tray is prepared in advance with brackets attached at exact positions based on digital planning, eliminating the need for manual positioning during the clinical procedure and significantly reducing chair time.
Solution Approach 2:
A customizable tray serves as an intermediary device between the digital treatment plan and the actual bracket placement on teeth. The tray acts as a mediator that holds multiple brackets in precise positions and transfers them to the patient's teeth simultaneously, reducing both time and manual complexity.
2Productivity
If indirect bonding trays are used to improve productivity, then chair time is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The tray design parameters are customized based on digital treatment planning software that allows adjustment of tray geometry, bracket positions, and support structures. By changing digital parameters rather than physical manufacturing parameters, the system achieves customization without increasing actual manufacturing complexity.
Solution Approach 2:
Traditional mechanical tray fabrication methods (thermoforming machines, compressed air systems) are replaced with 3D printing technology. This substitution eliminates the need for complex mechanical manufacturing equipment while achieving the same or better customization capabilities.
3Ease of manufacture
If traditional tray manufacturing equipment is used, then tray production is achieved, but cost and equipment requirements increase
Solution Approach 1:
The tray is designed as a disposable component that is 3D printed on-demand for each patient treatment. Rather than investing in expensive permanent manufacturing equipment, the system uses affordable 3D printing to create single-use trays that are discarded after one procedure, eliminating the need for costly manufacturing equipment.
Solution Approach 2:
Expensive traditional manufacturing equipment (thermoforming machines, compressed air systems) is replaced with accessible 3D printing technology. This substitution dramatically reduces equipment cost while maintaining or improving manufacturing capability for custom trays.
4Reliability
If manual tray preparation is used, then flexibility is maintained, but human error and reliability decrease
Solution Approach 1:
The system incorporates digital treatment planning software that provides virtual verification of bracket positions and tray design before actual fabrication. The digital model allows review and adjustment of all parameters, providing feedback mechanisms that eliminate human error in positioning and ensure high placement accuracy.
Solution Approach 2:
All positioning decisions and tray design parameters are finalized in advance through digital planning. The preliminary digital model is verified before manufacturing, eliminating the need for manual adjustments during the procedure and preventing human error in real-time操作中.
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
Reduces chair time, costs, and human error by enabling efficient, cost-effective, and precise bracket placement directly on teeth, minimizing manual steps and equipment requirements.
Implementation Method 1
printing, using a three-dimensional printer, the digital model of the orthodontic bracket, the digital model of the placement member, the digital model of the base member, and the digital model of the support member to form a physical orthodontic bracket system
Data Source
AI summary
An orthodontic bracket and bracket support system, and its method of manufacture and use is provided. The system includes a bracket assembly including one or more bracket members to be bonded to a patient's teeth, a placement guide assembly including one or more placement members to properly position the bracket members for the bonding procedure, and a support assembly to support the bracket assembly and/or the placement guide assembly during manufacture and use. The bracket assembly, the placement guide assembly, and the support assembly are formed together and in combination using stereolithography three-dimensional (3D) printing.