Implant-Supported Denture Design Using CAD/CAM and 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The traditional process of fabricating dentures is time-consuming and costly, requiring multiple visits between patients and healthcare professionals, with potential inadequacies in the fit of final dentures due to limitations in current manufacturing methods.
Innovation Solution
A method involving computer-aided design (CAD) and computer-assisted manufacturing (CAM) processes, including 3D printing, to create a virtual denture design that is then manufactured into a functional fitting replica with precise alignment and gingival architecture, reducing the number of steps and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual denture fabrication process is used, then dentures can be made with current manufacturing capabilities, but the process is time-consuming and costly requiring multiple patient visits
Solution Approach 1:
The patent applies preliminary action by creating a virtual denture design and functional fitting replica before the final denture fabrication. The virtual design phase allows all planning, tooth arrangement, and fit verification to be completed digitally before manufacturing, eliminating the need for multiple patient visits during the fabrication process. The functional fitting replica serves as a preliminary physical model that can be evaluated in advance.
Solution Approach 2:
The patent uses copying by creating a virtual copy of the patient's oral anatomy through digital scanning and impression taking. This virtual model is then used to fabricate the denture without requiring repeated physical impressions or patient presence. The functional fitting replica is also a copy that allows evaluation without damaging the final denture setup.
2Manufacturing precision
If traditional manufacturing methods are used, then dentures can be produced with existing processes, but the fit accuracy may be inadequate
Solution Approach 1:
The patent replaces manual mechanical processes with computer-aided design (CAD) and computer-assisted manufacturing (CAM) systems. The digital scanning, virtual modeling, and automated manufacturing processes provide superior precision compared to traditional hand-based methods. The software enables accurate tooth arrangement, occlusion planning, and fit verification that cannot be achieved through manual processes alone.
Solution Approach 2:
The virtual denture design phase allows all precision work to be completed before manufacturing. The software enables detailed planning of tooth position, occlusion, and fit characteristics in the virtual model, ensuring manufacturing precision is built into the design before physical fabrication begins.
3Ease of operation
If wax try-in dentures are used for patient evaluation, then fit and appearance can be assessed, but the setup may be damaged during bite registration
Solution Approach 1:
The patent creates a functional fitting replica as a separate copy from the final denture setup. This replica serves as the evaluation model that the patient wears and uses for bite registration, while the final denture setup remains untouched and protected. Any damage or wear occurs only to the replica, not to the final restoration.
Solution Approach 2:
The functional fitting replica is created in advance as a preliminary evaluation tool. It allows all patient assessments, adjustments, and bite registrations to be performed before the final denture is completed, protecting the final setup from damage during the evaluation process.
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 approach significantly reduces the time and cost of denture production, enhances the accuracy and fit of dentures, and allows for more efficient patient evaluation by enabling bite registration without damaging the setup.
Implementation Method 1
Additive processes include those known by terms such as three-dimensional (3D) printing, additive manufacturing, rapid prototyping and rapid manufacturing, and include processes of forming a three-dimensional solid objects from a virtually designed digital model.
Data Source
AI summary
The present application describes an implant-supported denture device and a method for designing and manufacturing an implant-supported denture device for a patient. A method is described for designing a virtual denture and manufacturing an implant-supported functional fitting replica denture from the virtual denture. An apparatus comprising a functional fitting replica denture is prepared having denture teeth having a fit substantially similar to the final denture. The methods and apparatus described herein reduce the number of visits required to manufacture the final denture.