Orthodontic Aligner Trimline Modeling for Precise CNC Trimming
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Solution Overview
Problem
Current methods for manufacturing orthodontic aligners face challenges such as complex trimming processes due to their intricate shapes and small sizes, leading to time-consuming manual trimming and costly CNC milling setups, which often result in suboptimal edge quality and prolonged treatment times.
Innovation Solution
A computer-implemented method and system for defining a trimline in a 3-D digital model of teeth, using margin points, control points, and splines to generate machine code for CNC machining, allowing for precise edge configuration and automated validation against clinical and machining parameters, reducing the need for manual modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual trimming with scissors is used, then flexibility in modifying aligners is improved, but time consumption and skill requirement increase significantly
Solution Approach 1:
The patent replaces manual mechanical trimming with automated CNC milling machinery. The system uses computer-controlled milling tools to automatically trim aligners based on digitally defined trimlines, eliminating the need for manual scissors trimming while maintaining precision and flexibility through software-controlled parameters.
Solution Approach 2:
The patent enables flexible modification of aligners by allowing clinicians to adjust trimline parameters digitally before manufacturing. Parameters such as trimline position, curvature, and distance from gingival margins can be modified through software, providing adaptability without requiring manual field modifications.
2Extent of automation
If CNC milling is used for trimming, then automation is improved, but setup complexity and cost increase
Solution Approach 1:
The patent uses digital copies of the patient's dentition in the form of 3D scanned models and virtual trimlines. These digital representations are used to program the CNC mill, replacing complex physical setup procedures with straightforward digital file import and processing.
Solution Approach 2:
The patent creates a universal digital workflow that can be applied to all aligner trimming cases. The same software platform and CNC machine setup can handle various trimline configurations and aligner types without requiring case-specific mechanical adjustments or specialized tooling.
3Extent of automation
If CNC milling is used for trimming, then automation is improved, but edge quality and complete separation capability worsen
Solution Approach 1:
The patent performs preliminary digital planning and validation of trimlines before manufacturing. The system checks trimline parameters against clinical and machining constraints in advance, ensuring optimal edge quality and complete separability are built into the digital design before the actual CNC cutting process.
Solution Approach 2:
The patent incorporates feedback mechanisms where the CNC machine's actual cutting results can be compared with the digital trimline model. This allows for validation and adjustment of trimming parameters to achieve the desired edge quality and complete separation.
Data Source
AI summary
Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.