3D Aligner Trimline Definition for Automated Laser Trimming
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Solution Overview
Problem
The manufacturing of orthodontic aligners is hindered by difficulties in trimming complex and small-sized dental models, with existing methods like CNC milling being expensive, time-consuming, and limited by spatial constraints, and manual modifications often compromising the aligner's performance.
Innovation Solution
A method and system that define a trimline for aligner manufacturing using a three-dimensional model of the patient's teeth, involving the generation of scallop planes, transition points, and connector curves to create a digital trimline, which can be edited and validated to ensure machinability and structural integrity, allowing for automated trimming and reducing the need for manual modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If CNC milling is used to trim aligners, then trimming can be automated, but the setup procedure is complicated and expensive, and spatial limitations prevent complete separation of some aligners
Solution Approach 1:
The patent replaces the mechanical CNC milling system with a laser-based trimming system. The laser trimmer uses optical energy to cut the plastic material of aligners, eliminating the need for complex mechanical setup procedures while maintaining automation. The laser system can access tight spaces and complex geometries that mechanical mills cannot, resolving the spatial limitations issue.
2Ease of operation
If manual trimming with scissors is used, then flexibility is maintained, but the process is time consuming and requires significant skill
Solution Approach 1:
The patent replaces manual mechanical trimming with an automated laser trimming system. The laser provides both the flexibility needed for complex shapes and the automation required for high productivity. The system can be controlled via software to precisely follow the desired trim path while operating at speeds much faster than manual trimming.
3Extent of automation
If CNC milling is used to trim aligners, then automation is achieved, but machined aligners require subsequent processing to improve edge quality
Solution Approach 1:
The laser trimming system inherently produces cleaner edges with less burr formation compared to mechanical milling. The laser's precise energy delivery melts and vaporizes material along the cut path, creating a smoother edge that requires minimal or no additional processing, thereby simplifying the manufacturing process while maintaining automation.
4Adaptability or versatility
If trimline changes are made for each aligner or group of aligners, then patient-specific customization is achieved, but the complexity of managing multiple trimlines increases
Solution Approach 1:
The laser trimming system is designed to be universally applicable across all aligners in a treatment series. A single laser trimmer can handle different trimline geometries and positions by receiving digital instructions, eliminating the need for multiple specialized tools or complex setup procedures for each aligner type.
Solution Approach 2:
The system allows easy modification of trimline parameters through software control. Changes in trimline position, shape, or orientation are implemented by updating digital design parameters rather than physically reconfiguring the trimming apparatus, greatly simplifying the management of patient-specific customizations.
Data Source
AI summary
Systems and methods of defining a trimline in relation to modeled teeth including a three-dimensional model of one or more intraoral surfaces of the patient. The trimline is for use to manufacture an aligner. For one or more pairs of adjacent teeth, a scallop plane is defined based on a scallop factor. The scallop plane is used to determine the position of scallop points on a line around each tooth adjacent to an interproximal region of the pair of teeth. Transition points are then defined on the line around each tooth apically of the scallop points, and the points connected to form an initial connector curve. The initial connector curve is projected on to a mesh of the three-dimensional model, and smoothing applied to the resulting segmented connector curve. The smoothed connector curves are then joined by teeth curves to form the trimline.