Clear Dental Aligner 3D Printing for Precise Force Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing methods for dental aligners and tooth movement appliances lack efficiency and accuracy in controlling the forces applied to teeth, which can impact the effectiveness of orthodontic treatments.
Innovation Solution
A direct 3D printing process that involves scanning teeth, developing a force vector matrix to determine necessary forces, and printing dental aligners with force augmentation geometries or generators to precisely move teeth to desired positions, using computer-executable fabrication instructions and selective light curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing methods are used for dental aligners, then manufacturing simplicity is maintained, but manufacturing precision and force control accuracy deteriorate
Solution Approach 1:
The aligner is divided into multiple layers during 3D printing, with each layer containing specific geometric features that contribute to force application. This segmentation allows precise control of force distribution while maintaining manufacturing feasibility through layer-by-layer additive construction.
Solution Approach 2:
The patent implements varying thickness, density, and material properties at different locations within the aligner structure. Force-critical regions have enhanced geometric features while non-critical regions maintain standard properties, optimizing force control accuracy without unnecessarily increasing overall complexity.
2Manufacturing precision
If force augmentation geometries are added to 3D printed aligners, then force application control is improved, but manufacturing complexity increases
Solution Approach 1:
The force augmentation geometries are integrated directly into the aligner body during the same 3D printing process, merging the force application mechanism with the retainment structure. This eliminates separate components and reduces assembly complexity while achieving precise force control.
Solution Approach 2:
The patent introduces geometric complexity in the z-dimension (thickness variations, embedded features) rather than adding lateral components. Force augmentation is achieved through vertical layer design and internal geometry modification, maintaining external simplicity while enhancing internal force control capabilities.
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 the accuracy and control of force application, leading to more effective tooth movement and improved treatment outcomes.
Implementation Method 1
selective light curing, via the 3D printer, the liquid resin into a solid surface
Data Source
AI summary
Processes for producing dental aligners and/or appliances and dental aligners and/or appliances produced by the processes are provided, wherein the processes comprise making a scan of teeth of a patient and developing a treatment plan for moving at least one tooth of the teeth from an original or first position to a new, final, or second position. The processes further comprise developing a force vector matrix, wherein the force vector matrix comprises all variables that are known to contribute to force generation of an orthodontic appliance on a patient's tooth, and 3D printing the dental aligner or appliance based on the developed treatment plan, the developed force vector matrix, and/or the scan of the teeth of the patient.