CAD-Milled Dental Device Matrix for Custom Sleep Apnea Fit
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Solution Overview
Problem
Current dental devices for treating sleep apnea are handmade, limiting the ability to produce multiple customized devices for a patient, resulting in suboptimal fit and increased economic burden due to the need for multiple laboratory consultations.
Innovation Solution
A method involving computer-aided design (CAD) software to create digital models of patients' dentition, incorporating clinical options, and automated milling of polymer blocks to produce customized mandibular advancement devices, allowing for precise and efficient manufacturing of multiple device variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dental devices are hand-crafted artisanally to health care provider's specification, then each laboratory can manufacture one type or select few of the options, but it is economically impossible to prepare multiple sets of devices for a patient
Solution Approach 1:
The patent applies parameter changes by utilizing computer-aided design (CAD) software to digitally modify device parameters such as mandibular advancement distance, splint geometry, and material properties. This allows multiple device variations to be generated from a single patient scan by changing digital parameters rather than physically remaking each device, thereby enabling cost-effective production of multiple device sets for the same patient.
Solution Approach 2:
The patent employs copying by creating digital replicas of patient dentition through intraoral scanning, then generating multiple virtual models with different treatment parameters. These digital copies can be rapidly iterated and manufactured without requiring new physical impressions or manual craftsmanship for each variation, significantly increasing productivity while maintaining customization.
2Adaptability or versatility
If multiple laboratories are contacted to prepare different styles of mandibular advancement devices, then more device options are available, but the economic burden increases and treatment efficiency decreases
Solution Approach 1:
The patent implements universality by developing a single integrated CAD platform that can generate multiple device styles and configurations within one system. The software provides a comprehensive library of splint designs, connection mechanisms, and adjustment features that can be combined in various ways to create different device options, eliminating the need to outsource to multiple specialized laboratories while maintaining diverse stylistic and functional choices.
Solution Approach 2:
The patent applies preliminary action by pre-programming the CAD software with multiple device design templates, material selections, and manufacturing parameters before the actual device creation process. This allows the system to rapidly generate and evaluate multiple device options during the design phase, enabling the health care provider and patient to review and select from various styles and configurations without time-consuming iterative consultations with multiple laboratories.
3Manufacturing precision
If dental devices are customized to patient anatomy, then optimal fit and comfort are achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical system of manual device fabrication with an automated computer-aided manufacturing (CAM) system. The CAD software generates precise 3D models of customized devices that directly interface with CNC milling machines or 3D printers, which automatically manufacture the devices with high precision. This substitution of manual craftsmanship with automated manufacturing maintains exact anatomical fit while significantly reducing the complexity and cost of the customization process.
Data Source
AI summary
Disclosed herein are methods of manufacturing a dental device, the method comprising: obtaining a set of clinical options for the dental device from a health care provider; creating a first data set from the set of clinical options; communicating the data set to a computer aided design (CAD) software; preparing a digital design for the dental device using the CAD software; communicating the digital design to an automated milling apparatus; and automatedly milling a block of polymer to obtain the dental device. Also disclosed are dental devices manufactured by the above method. Further disclosed are methods of treating or ameliorating apnea jaw-related disorder in a patient, the method comprising obtaining a dental device manufactured by the above method and positioning the dental device over the dentition prior to sleep, whereby the mandible is advanced forward relative to the maxilla, thereby ameliorating the symptoms of sleep apnea or the jaw-related disorder.