Orthodontic Aligner Additive Manufacturing Without Support Traces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing mouthpieces using additive manufacturing result in support traces or marks on the surface, which can lead to aesthetic issues, especially in transparent mouthpieces, as they cause color unevenness and discomfort when viewed.
Innovation Solution
A method for manufacturing a mouthpiece that involves performing additive manufacturing to create a product with a peripheral portion and supports, and then removing the peripheral portion to prevent support traces from forming on the mouthpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If supports are formed during additive manufacturing to support the peripheral portion, then the manufacturing process is enabled, but support traces or marks are formed on the mouthpiece surface causing aesthetic issues
Solution Approach 1:
The invention divides the mouthpiece into two functional parts: the mouthpiece body and the peripheral portion. The peripheral portion is specifically designed to be removable and is used only during manufacturing to support overhang structures. After manufacturing, the peripheral portion is removed, leaving no support traces on the mouthpiece surface. This segmentation allows the manufacturing process to use supports while the final product remains trace-free.
Solution Approach 2:
The peripheral portion is extracted as a separate removable component from the final mouthpiece product. It is added only during the additive manufacturing process to enable formation of overhang structures, and then completely removed afterward. This extraction ensures that any support traces are eliminated from the final product while still allowing the manufacturing process to proceed.
2Manufacturing precision
If the entire surface of the mouthpiece is polished to remove support traces, then aesthetics are improved, but the polishing process takes a lot of time especially for concave areas
Solution Approach 1:
The peripheral portion is designed to be removed before the polishing process. By removing the peripheral portion (which contains the support traces) in advance, the polishing process only needs to treat the mouthpiece body surface, significantly reducing the time and effort required compared to polishing the entire surface including concave areas.
3Manufacturing precision
If supports are removed from the manufactured product, then support traces are eliminated, but the manufacturing process becomes more complex
Solution Approach 1:
The mouthpiece is segmented into the mouthpiece body and the peripheral portion, where the peripheral portion is specifically designed as a removable manufacturing aid. This segmentation allows for a standardized removal process that, while adding a step, provides consistent results and simplifies the overall process by using a dedicated component for support functions.
Solution Approach 2:
The peripheral portion is extracted as a separate removable component that serves only during manufacturing. By isolating the support function into a separate removable part, the main mouthpiece body can be manufactured with simple, clean surfaces without complex support structures integrated into the final design.
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 allows for the creation of mouthpieces with no support traces, improving aesthetics without the need for polishing and enhancing the fit and comfort when worn.
Implementation Method 1
performing additive manufacturing for manufacturing a manufactured product
Data Source
Figure 1
Figure 2
Figure 3
AI summary
To provide a mouthpiece without a support trace and a method for manufacturing the mouthpiece. A method for manufacturing a mouthpiece (orthodontic aligner (20)), wherein the mouthpiece is to be placed within an oral cavity to cover teeth (10) and manufactured by an additive manufacturing device (30), the method including performing additive manufacturing for manufacturing a manufactured product (40) that comprises the mouthpiece (orthodontic aligner (20)), a peripheral portion (28) connected to the mouthpiece (orthodontic aligner (20)), and a support (26) configured to support the peripheral portion (28), and removing the peripheral portion (28) from the manufactured product (40).