3D-Printed Orthodontic Shells With Active Elements for Fewer Aligners
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Solution Overview
Problem
Existing orthodontic treatments using consecutive transparent shells have limited movement capabilities due to shell elasticity, requiring numerous intermediate positions and prolonged treatment durations, with limited orthodontist adjustment options after initial design.
Innovation Solution
An orthodontic appliance with integrally formed shells featuring modified active elements that apply specific forces through 3D printing, allowing for increased movement and reduced intermediate positions, manufactured by an orthodontist using a 3D printer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermoforming process is used to manufacture shells, then manufacturing precision and uniform thickness are difficult to achieve, but the process is well-established and equipment is readily available
Solution Approach 1:
The patent replaces the conventional thermoforming mechanical process with additive manufacturing (3D printing). This substitution enables precise control over shell thickness and geometry through digital modeling, achieving uniform thickness that is difficult to obtain through thermal forming processes.
Solution Approach 2:
The invention changes the manufacturing parameters from thermal processes to additive deposition processes. By using layer-by-layer material deposition with controlled thickness parameters, the system achieves precise thickness control and geometric accuracy that cannot be obtained through conventional thermoforming.
2Length of moving object
If shell elasticity is limited, then movement capacity between intermediate positions is restricted, but the shells maintain structural integrity
Solution Approach 1:
The patent applies local quality by creating regions of different stiffness within the shell structure. The active elements have modified material properties or geometric configurations that provide higher flexibility in specific areas, allowing greater teeth movement capacity while the overall shell maintains sufficient structural integrity through varying local mechanical properties.
Solution Approach 2:
The invention uses composite material structures with varying properties throughout the shell. By combining materials or structural configurations with different elastic moduli in specific regions, the shell achieves both the flexibility needed for teeth movement and the overall strength required for structural integrity.
3Measurement precision
If numerous intermediate positions are required to achieve final tooth position, then treatment duration increases, but the final alignment accuracy is improved
Solution Approach 1:
The patent introduces dynamic adjustability to the shell system through active elements that can be modified between treatment stages. This allows the orthodontist to adjust the treatment plan and intermediate positions dynamically, reducing the number of required shells while maintaining alignment accuracy through adaptive force application.
Solution Approach 2:
The invention implements preliminary action by incorporating active elements that pre-position teeth closer to the final target position. These elements apply optimized forces in advance, enabling larger movements per shell and reducing the total number of intermediate positions needed to achieve the final alignment.
4Adaptability or versatility
If orthodontist needs to adjust treatment after initial design, then new shells must be manufactured, but treatment adaptability is improved
Solution Approach 1:
The patent enables dynamic treatment adjustment by designing shells with active elements that can be modified or replaced. This allows the orthodontist to adapt the treatment plan mid-course without manufacturing entirely new shells, improving treatment flexibility while maintaining manufacturing efficiency through incremental modifications.
Solution Approach 2:
The invention segments the shell into modular components, including replaceable active elements. This segmentation allows selective modification of specific regions or elements rather than remanufacturing the entire shell, enabling treatment adjustments while preserving manufacturing productivity through partial rather than complete reconstruction.
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
Enhances treatment efficiency by reducing the number of intermediate positions and treatment duration, enabling precise force application and adjustment, while maintaining uniform shell thickness.
Implementation Method 1
The capacity for movements in between consecutive intermediate positions is limited by the elastic deformation of the shells.
Implementation Method 2
Suitable printing processes include vat polymerization, which is a method in 3D printing that utilizes a vat of liquid polymer resin by exposing it to ultraviolet light for solidification.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
Orthodontic appliances are disclosed, comprising an integrally formed shell including a first shell part comprising one or more first cavities adapted to receive the first teeth of the patient, a second shell part comprising one or more second cavities adapted to receive the second teeth of the patient, and a modified active shell part connecting the first shell part and the second shell part, and wherein the modified active shell part comprises one or more active elements configured to apply forces to the first and/or the second shell part. The disclosure further relates to methods for manufacturing an orthodontic appliance, to computer-implemented methods for generating an input file for a 3D printer and to kits comprising series of consecutive shells.