3D Printed Orthodontic Shells With Variable Thickness Force Control
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Solution Overview
Problem
Existing orthodontic appliances often lack sufficient control over the forces applied to teeth, and the use of power arms can be less than ideal, particularly when employing homogeneous and/or continuous material properties.
Innovation Solution
Orthodontic appliances with variable localized properties, such as heterogeneous thickness, stiffness, and material composition, are produced using direct fabrication techniques to provide precise control over force and torque application, incorporating integrally formed features like power arms and connecting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If homogeneous and continuous material properties are used in orthodontic appliances, then manufacturing simplicity is maintained, but control over forces applied to teeth is insufficient
Solution Approach 1:
The patent implements variable thickness regions within the appliance shell, creating areas of different stiffness to control force application at specific locations. The shell transitions from uniform thickness to having distinct thick and thin regions, allowing precise control over where and how forces are applied to teeth during orthodontic treatment.
Solution Approach 2:
The appliance is divided into multiple functional regions with different thickness properties. The shell is segmented into thick regions for structural support and force application, and thin regions for flexibility and comfort, enabling differentiated force control across different areas of the appliance.
2Manufacturing precision
If variable thickness regions are incorporated into the appliance, then control over force and torque application is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes 3D printing technology to directly fabricate the appliance with variable thickness regions, changing the manufacturing parameter from traditional molding to additive manufacturing. This enables complex geometric variations in shell thickness that would be difficult to achieve with conventional manufacturing methods.
Solution Approach 2:
The patent moves from 2D uniform shell design to 3D variable thickness design, utilizing the third dimension (depth/thickness) to create functional gradients within the appliance structure. This dimensional addition allows for complex force control while maintaining a single-piece construction.
3Manufacturing precision
If integrally formed power arms are incorporated into the appliance, then tooth movement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent integrates power arms directly into the appliance shell as an integral component, merging two previously separate elements (shell and power arms) into a single unified structure. This integral formation ensures precise positioning and eliminates alignment issues between separate components.
Solution Approach 2:
The appliance shell serves multiple functions: it provides the primary orthodontic force through its variable thickness design, incorporates attachment points for teeth, and integrates power arm structures for additional force application. This multi-functionality reduces the need for separate auxiliary devices.
Data Source
AI summary
Dental appliances for treatment of a patient's dentition are provided. In some embodiments, a dental appliance includes a plurality of 3D printed polymer layers, where the plurality of 3D printed polymer layers includes a plurality of sequentially polymerized appliance cross-sections. The dental appliance can include an appliance shell formed from the plurality of sequentially polymerized appliance cross-sections. The appliance shell can include a plurality of tooth receiving cavities formed from the plurality of sequentially polymerized appliance cross-sections, the plurality of tooth receiving cavities arranged to receive a dentition and to exert one or more forces on the dentition, and a plurality of variable thickness regions formed from the plurality of sequentially polymerized appliance cross-sections. The plurality of variable thickness regions can include a corresponding plurality of different appliance thicknesses, and the plurality of variable thickness regions can be arranged to implement one or more treatment outcomes.