Dental Aligner Model Positioning for Automated Edge Trimming
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Solution Overview
Problem
The manufacturing process of dental aligners is time-consuming and expensive due to the need for custom-fit creation and removal of extraneous material, which can cause discomfort if not properly handled, and existing methods often require manual hand-cutting, leading to inefficiencies.
Innovation Solution
A method and system that utilize a digital model with a locator feature to create a physical model of teeth, allowing for the formation and subsequent removal of extraneous material from dental aligners using a milling system, ensuring precise alignment and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual hand-cutting is used to remove extraneous material, then the aligner device can be customized to fit the patient's mouth, but the production time and cost increase significantly
Solution Approach 1:
The patent replaces manual mechanical hand-cutting with an automated computer-controlled milling system. The milling system uses a rotating cutting tool guided by digital models to automatically remove extraneous material from the aligner device, eliminating the need for manual operation while maintaining precision. This substitution of manual mechanical work with automated mechanical systems resolves the contradiction between customization precision and production efficiency.
2Productivity
If extraneous material is not removed, then the manufacturing process is faster and cheaper, but the aligner device causes discomfort to the wearer
Solution Approach 1:
The patent incorporates the removal of extraneous material as a preliminary step in the manufacturing process, performed by the automated milling system before the aligner device is completed and delivered to the patient. By addressing the potential harm (discomfort from extraneous material) in advance during manufacturing, the system ensures both efficiency and comfort without requiring post-manufacturing adjustments.
3Productivity
If automated milling is used to remove extraneous material, then production time and cost are reduced, but precise positioning of the physical model is required
Solution Approach 1:
The patent introduces a positioning mechanism as an intermediary between the physical model and the milling system. This positioning mechanism ensures accurate alignment and stable positioning of the physical model during the automated milling process. By incorporating this intermediary positioning system, the patent enables automated high-speed milling while maintaining the precision required for custom-fit aligner devices, thus resolving the contradiction between production speed and positioning accuracy.
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.