Orthodontic Aligner Fabrication Deviation Compensation
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Solution Overview
Problem
Direct fabrication of orthodontic aligners often results in inaccuracies and defects, leading to less desirable treatment outcomes, and existing aligners have consistent thickness that may cause premature wear and inadequate movement forces.
Innovation Solution
The method involves generating three-dimensional models of aligners with compensation for potential deviations during fabrication using predictive models and real-time correction, incorporating parameters such as material properties, fabrication settings, and sensor data to improve accuracy and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct fabrication of aligners is used, then production time is reduced and waste is minimized, but fabrication accuracy and quality deteriorate
Solution Approach 1:
The system performs preliminary actions by generating predictive models of fabrication deviations before actual fabrication occurs. These models anticipate potential errors in direct fabrication and pre-calculate compensation parameters that are then applied to the fabrication instructions, allowing accurate alignment without traditional molding steps.
Solution Approach 2:
The system implements feedback by using sensor data from the fabrication process to update and refine predictive models in real-time. This closed-loop approach allows the system to learn from actual fabrication outcomes and improve compensation accuracy for subsequent aligner productions, maintaining high precision in direct fabrication.
2Ease of manufacture
If aligners have consistent thickness, then manufacturing is simplified, but durability decreases and movement forces become inadequate
Solution Approach 1:
The system applies local quality by varying the thickness of different regions of the aligner based on specific functional requirements. Critical areas such as bite ramps and attachment regions are thickened to enhance durability and force transmission, while non-critical areas maintain standard thickness. This region-specific optimization is achieved through computational modeling that identifies stress distribution patterns.
Solution Approach 2:
The system utilizes parameter changes by dynamically adjusting thickness parameters across different zones of the aligner design. The computational system calculates optimal thickness values for each region based on mechanical requirements, material properties, and intended tooth movement forces, then incorporates these variations into the fabrication model.
3Manufacturing precision
If predictive models with multiple parameters are used, then fabrication accuracy improves, but computing resources increase
Solution Approach 1:
The system applies partial action by implementing a hierarchical modeling approach that focuses computational resources on the most critical fabrication parameters and regions. Rather than calculating all possible deviations with equal detail, the system identifies and prioritizes the top factors that have the greatest impact on alignment accuracy, applying full predictive modeling only where needed.
Solution Approach 2:
The system performs preliminary action by pre-calculating and storing compensation parameters for common fabrication scenarios and material types. This allows the system to quickly retrieve and apply pre-computed correction values for routine cases, reserving intensive real-time computation only for novel or complex situations that require customized predictive modeling.
Data Source
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AI summary
A method for use in additively manufacturing an orthodontic aligner may include receiving a digital model of an aligner, processing the digital model of the aligner to modify the digital model based on predicted deviations during fabrication to generate a first updated digital model of the aligner, determining that whether the predicted deviations of a physical aligner additively manufactured based on the first updated digital model of the aligner are acceptable, and outputting the first updated digital model of the aligner for fabrication of the physical aligner by additive manufacture of the physical aligner.