Dental Aligner Locator Features for Automated Trim Removal
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Solution Overview
Problem
Existing dental aligner manufacturing processes are time-consuming and expensive due to the need for manual removal of extraneous material, which can cause discomfort and require precise handling to avoid sharp tips or valleys.
Innovation Solution
A method and system that utilizes a locator feature in digital models to facilitate automated removal of extraneous material from dental aligners using a milling system, guided by a locator keyway for precise alignment and cutting paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual removal of extraneous material is used, then precision and comfort are improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces manual mechanical removal with an automated milling system that uses computer-controlled cutting tools to remove extraneous material. The milling system includes a milling tool, positioning system, and control unit that work together to automatically mill the extraneous material based on digital model data, eliminating manual labor while maintaining precision.
Solution Approach 2:
The system enables self-service by having the milling system automatically position and mill the extraneous material without human intervention. The positioning system automatically aligns the aligner device with the digital model, and the control unit automatically controls the milling process, allowing the system to service itself.
2Productivity
If automated milling is used, then manufacturing efficiency is improved, but positioning precision requirements increase
Solution Approach 1:
The patent introduces a positioning system as an intermediary between the milling system and the aligner device. This positioning system includes positioning elements that engage with corresponding features on the aligner device holder, acting as a mediator to ensure precise and repeatable positioning. The positioning system translates digital positioning data into physical alignment, bridging the gap between automated control and precise mechanical positioning.
3Productivity
If extraneous material is not removed, then manufacturing time is reduced, but wearer comfort deteriorates
Solution Approach 1:
The patent applies preliminary action by removing the extraneous material immediately after the aligner device is formed, before any wear or storage occurs. The milling process is integrated into the manufacturing sequence, so that as soon as the aligner device is created, the extraneous material is automatically milled away, ensuring the device is ready for use without requiring separate manual trimming steps.
Data Source
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.