CAD-Milled Dental Splints 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 styles or combinations for a patient, leading to suboptimal fit and effectiveness.
Innovation Solution
A method involving computer-aided design (CAD) and automated milling to create customized dental devices, including upper and lower splints with adjustable fins, allowing for precise fit and mandibular advancement.
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 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 fin configurations. This allows multiple device variations to be generated from a single patient scan by changing digital parameters rather than physical manufacturing constraints, enabling cost-effective production of multiple device options tailored to individual patient anatomy and treatment requirements
Solution Approach 2:
The patent employs copying by creating multiple digital copies of the base device design with varying parameters through CAD software. Instead of manually crafting each device variant, the system generates digital copies with modified characteristics (different advancement distances, splint thicknesses, fin positions) that can be rapidly manufactured using automated milling, thereby enabling economical production of multiple device sets for the same patient
2Adaptability or versatility
If multiple laboratories are contacted to prepare different styles of mandibular advancement devices, then more device options are available, but it is economically impossible to prepare multiple sets of devices for a patient
Solution Approach 1:
The patent implements universality by creating a single integrated CAD system that can generate multiple device styles and configurations from one patient scan. The universal platform allows health care providers to access various device types (mandibular advancement devices, splints, combinations) and customize them digitally, eliminating the need to contact multiple laboratories while still providing diverse device options tailored to individual patient needs
Solution Approach 2:
The patent applies segmentation by dividing the device into modular components (upper splint, lower splint, fins, connectors) that can be independently designed and configured in the CAD software. This modular approach allows rapid generation of multiple device combinations by mixing and matching segmented components, enabling cost-effective production of various device styles without requiring multiple laboratories
3Manufacturing precision
If dental devices are hand-crafted, then customization to patient anatomy is possible, but the fit and effectiveness may be suboptimal
Solution Approach 1:
The patent replaces the manual mechanical crafting process with automated computer-aided design and computer-aided manufacturing (CAD/CAM) systems. The digital workflow substitutes human artisanal skill with algorithmic precision, using software to calculate optimal device geometry and automated milling machines to manufacture the device, thereby achieving superior manufacturing precision and fit while reducing manual manufacturing complexity
4Productivity
If automated milling is used to manufacture dental devices, then multiple device options can be produced cost-effectively, but the manufacturing process requires digital design infrastructure
Solution Approach 1:
The patent applies preliminary action by performing patient anatomy scanning and digital device design before manufacturing. The CAD software pre-calculates optimal device parameters based on the patient scan and treatment requirements, creating a complete digital blueprint that guides the automated milling process. This preliminary digital planning enables rapid production of multiple device variants without requiring complex manufacturing infrastructure during the actual manufacturing phase
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.