Automated Dental Aligner Blocking via Virtual Model Interpolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing dental aligners are labor-intensive due to manual handling of undercuts and interdental spaces, which complicates the blocking process and can lead to aligner binding issues.
Innovation Solution
A method that captures a virtual model of teeth, segments and interpolates interdental surfaces, automatically determines and removes surface elements associated with undercuts and interdental spaces, and uses interpolation to close gaps, simplifying the blocking process through algorithms and deep drawing of synthetic material foils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual blocking of undercut portions is performed, then aligner binding is prevented, but labor intensity and time consumption increase
Solution Approach 1:
The system performs self-blocking by automatically identifying undercut portions through virtual model analysis and executing blocking operations without manual intervention. The computer automatically determines which areas require blocking and applies synthetic material precisely to those locations, eliminating the need for manual blocking while ensuring consistent results.
Solution Approach 2:
Manual mechanical blocking operations are replaced with automated computational methods. The system uses virtual model processing, surface analysis algorithms, and automated material application to substitute the manual mechanical process of blocking, significantly reducing labor intensity while maintaining or improving blocking quality.
2Reliability
If manual blocking of undercut portions is performed, then aligner binding is prevented, but process complexity increases
Solution Approach 1:
The blocking process is segmented into distinct automated stages: virtual model capture, tooth segmentation, undercut portion identification through surface analysis, and targeted blocking material application. This segmentation transforms a complex manual process into manageable automated steps that can be executed systematically by the computer system.
Solution Approach 2:
Complex manual blocking operations are replaced with automated computational analysis and robotic or automated material application systems. The computer executes algorithms to identify undercuts and automatically applies blocking material, reducing process complexity despite the advanced technology involved.
3Manufacturing precision
If interdental surfaces are included in the model, then complete tooth structure is represented, but computational complexity and processing time increase
Solution Approach 1:
Interdental surfaces are extracted and separated from the individual tooth models during the virtual model processing stage. This extraction allows the blocking algorithm to focus specifically on undercut portions of individual teeth without being computationally burdened by complex interdental geometry, reducing processing time while preserving necessary structural information.
Solution Approach 2:
Interdental surfaces are pre-processed and prepared in advance before the blocking operation. The system performs preliminary segmentation and surface preparation, identifying and setting aside interdental areas so that the subsequent blocking process can proceed more efficiently without recalculating the entire model.
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
This method significantly simplifies the blocking process, preventing aligner binding and reducing complexity, allowing for quick and economic production of dental aligners that are comfortable and effective for tooth alignment.
Implementation Method 1
hardening the synthetic material foil on the real model to form the aligner
Data Source
AI summary
A method for producing an aligner for teeth of a patient, the method including initially capturing a virtual current model of the teeth with a current position of the teeth: segmenting the teeth in the virtual current model and interpolating interdental surfaces of the teeth; generating a virtual nominal model of the teeth including undercut portions from the virtual current model; automatically determining the undercut portions in the virtual nominal model; automatically removing all surface elements that are associated with the undercuts from the virtual nominal model; subsequently closing gaps in the virtual nominal model created by removing the surface elements wherein closing the gaps is performed by interpolation for blocking out; automatically blocking out the undercut portions in the virtual nominal model to produce a blocked out virtual nominal model; producing a real model of the teeth based on the blocked out virtual nominal model; applying a synthetic material foil to the real model by a deep drawing method; and hardening the synthetic material foil on the real model to form the aligner and removing the aligner from the real model.