Customized Ceramic Orthodontic Brackets via DLP Fabrication
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Solution Overview
Problem
Current orthodontic bracket manufacturing techniques lack precision and aesthetics, with no efficient method for creating custom ceramic labial or lingual brackets, leading to inaccuracies and increased treatment time and cost.
Innovation Solution
The use of digital light processing (DLP) additive manufacturing to create customized ceramic orthodontic brackets, allowing for in-office fabrication with high accuracy and aesthetic options, utilizing 3D CAD models and light-polymerizable materials like Aluminum Oxide and Zirconium Oxide ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional preformed brackets are used, then manufacturing cost is low and ease of manufacture is high, but manufacturing precision and customization capability are insufficient
Solution Approach 1:
3D scans or impressions of the dentition are taken and processed in advance to create digital models and design custom brackets before fabrication. This preliminary digital planning enables precise customization while streamlining the actual manufacturing process through automated additive production.
Solution Approach 2:
The bracket design parameters (position, angle, torque, depth) are customized for each patient based on their specific dental anatomy and treatment requirements. The additive manufacturing process enables variable parameter control throughout the bracket structure, achieving high precision placement accuracy.
2Manufacturing precision
If custom metal brackets are fabricated using selective laser melting, then customization capability is improved, but surface finish quality and resolution are insufficient
Solution Approach 1:
The patent replaces thermal-based selective laser melting with a photopolymerization-based stereolithography process. Light curing of photoresin material layer-by-layer produces superior surface finish quality and finer resolution details compared to thermal melting, while enabling direct fabrication without extensive post-processing.
Solution Approach 2:
The patent uses composite photoresin materials that can be cured through photopolymerization to create brackets with both high precision geometry and excellent surface finish. The material properties are optimized for both aesthetic appearance and mechanical performance.
3Manufacturing precision
If indirect bonding is used for custom bracket positioning, then adaptability to individual teeth is improved, but inherent error in the bracket itself remains
Solution Approach 1:
The bracket slot position, angle, and orientation are precisely determined during the digital design phase based on the patient's specific dental anatomy and treatment plan. The custom-fabricated bracket is manufactured with these precise parameters built-in, eliminating the need for indirect bonding and subsequent error introduction.
Solution Approach 2:
The patent creates a direct digital copy of the patient's dental anatomy through 3D scanning, then uses this accurate digital model to design and manufacture the custom bracket. This direct digital workflow eliminates intermediate physical steps that introduce error, achieving high precision slot positioning.
4Productivity
If standard non-custom brackets are used, then ease of manufacture is high, but treatment time increases due to compensation bends and adjustments
Solution Approach 1:
All bracket parameters including slot position, angle, torque, and depth are pre-calculated and built into the custom bracket design before fabrication. This eliminates the need for time-consuming compensation bends and adjustments during patient visits, significantly improving treatment efficiency.
Solution Approach 2:
Each bracket is customized with locally optimized parameters specific to each tooth's anatomy and treatment requirements. This localized customization eliminates the need for universal compensation adjustments, reducing treatment time and improving overall productivity.
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 method enables precise, efficient, and cost-effective production of custom ceramic brackets with improved accuracy and aesthetics, reducing treatment time and errors, and allowing for in-office fabrication by trained orthodontic professionals.
Implementation Method 1
digital light processing (DLP) additive manufacturing to create customized ceramic orthodontic brackets
Data Source
AI summary
A method of manufacturing customized ceramic labial/lingual orthodontic brackets by digital light processing, said method comprises measuring dentition data of a profile of teeth of a patient, wherein measuring dentition data is performed using a CT scanner or intra-oral scanner, based on the dentition data, creating a three dimensional computer-assisted design (3D CAD) model of the patient's teeth using reverse engineering, and saving the 3D CAD model on a computer, designing a 3D CAD bracket structure model for a single labial or lingual bracket structure, importing the 3D CAD bracket structure model into a Digital Light Processing (DLP) machine, directly producing the bracket by layer manufacturing.