Dental Aligner Trimming Using Locator-Guided Milling

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Solution Overview

Problem

Existing dental aligner devices are time-consuming and expensive to manufacture due to the need for manual removal of extraneous material, which can cause discomfort and require precise handling to avoid sharp edges.

Innovation Solution

A manufacturing system that includes a CAD system to add a locator feature to a digital model, a 3D printing system to create a physical model, a thermoforming system to form a dental aligner device, and a milling system to remove extraneous material using the locator feature, ensuring accurate alignment and efficient production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual removal of extraneous material is used, then precision in avoiding sharp edges is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improveprecision in avoiding sharp edgesVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical removal with automated CNC milling machinery. The system uses computer-controlled cutting tools to automatically remove extraneous material based on digital models, eliminating the need for manual hand-cutting while maintaining precision through programmed tool paths and automated positioning systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates self-positioning mechanisms where the aligner device itself is used as a reference for the milling process. The cutting tool automatically positions relative to the aligner's geometry, allowing the workpiece to guide its own processing without manual intervention for positioning or measurement.

Inventive Principle:

Principle #25Self-service

2Object-affected harmful factors

If manual removal of extraneous material is used, then comfort for the wearer is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecomfort for the wearerVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent replaces expensive manual craftsmanship with automated CNC milling systems. The computer-controlled machinery eliminates the need for skilled manual labor while consistently producing comfortable results through precise, repeatable removal of extraneous material based on digital designs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses digital 3D models as exact copies of the desired final geometry. These digital templates guide the automated milling process, ensuring that extraneous material is removed precisely to the designed boundaries without creating uncomfortable sharp edges, while the process can be replicated indefinitely without additional cost.

Inventive Principle:

Principle #26Copying

3Productivity

If automated milling is used to remove extraneous material, then manufacturing time is reduced, but positioning precision is challenged

Engineering Contradiction:

Improvemanufacturing timeVSAvoidpositioning precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces manual positioning with automated computer-controlled positioning systems. CNC machines use digital models and programmed coordinates to automatically position cutting tools with high precision, eliminating human error in measurement and positioning while maintaining speed through automated operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates feedback mechanisms where the digital model continuously guides the milling process. The programmed tool paths are based on precise digital representations of the aligner geometry, and the system can detect and compensate for positioning deviations, ensuring accurate removal of extraneous material throughout the automated process.

Inventive Principle:

Principle #23Feedback

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

The system significantly reduces manufacturing time and cost by automating the removal of extraneous material, ensuring precise alignment and comfort for the wearer.

Implementation Method 1

a printing system configured to create a physical model of the teeth based on the modified digital model

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Implementation Method 2

a forming system configured to form a dental aligner device on the physical model of the teeth

Methodology Applied

Scientific EffectThermoforming: Heating

Implementation Method 3

a milling system configured to remove the extraneous material from the dental aligner device from the physical model of the teeth

Methodology Applied

Scientific EffectMilling: Abrasion

Data Source

PatentUS12458471B2Dental device manufacturing system and method

Publication Date: 2025.11.04 MERIT CABOT LLC

AI summary

A manufacturing system and method obtain a first digital model of teeth, create a modified digital model of the teeth by adding a locator feature to the first digital model of the teeth, and create a physical model of the teeth based on the modified digital model. A portion of the physical model is created based on the locator feature. A dental aligner device is formed on the physical model of the teeth with extraneous material of the dental aligner device extending away from the dental aligner device. The extraneous material is removed from the dental aligner device from the physical model of the teeth. The forming of the dental aligner device and/or the removing of the extraneous material is performed by positioning the physical model using the locator feature.