Customized Ceramic Orthodontic Brackets via DLP Printing
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Solution Overview
Problem
Current orthodontic bracket manufacturing techniques lack the ability to create custom, aesthetically pleasing, and accurately positioned ceramic labial and lingual brackets, leading to inefficiencies and inaccuracies in treatment due to the use of preformed brackets and indirect bonding methods.
Innovation Solution
The development of a digital light processing (DLP) additive manufacturing method for creating customized ceramic orthodontic brackets, which involves measuring dentition data, designing a 3D CAD model, and producing the brackets layer by layer using a DLP machine with high accuracy and precision, allowing for in-office fabrication and customization of bracket shape, size, and placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If preformed brackets are used with indirect bonding methods, then manufacturing complexity is reduced, but manufacturing precision and placement accuracy deteriorate
Solution Approach 1:
The patent replaces traditional mechanical indirect bonding methods with a digital light processing (DLP) additive manufacturing system. The DLP machine uses digital light projection and photopolymerization to directly fabricate custom brackets in-office based on patient-specific 3D scans, eliminating the need for physical molds and indirect bonding procedures while achieving superior placement accuracy of less than 0.2mm.
Solution Approach 2:
The invention changes the manufacturing parameters from mass-produced standardized brackets to patient-specific custom parameters. The system captures individual tooth morphology through 3D scanning and uses this data to generate unique bracket designs with customized slot positions, base contours, and engagement features that precisely match each patient's dentition, thereby improving placement accuracy.
2Adaptability or versatility
If custom metal lingual brackets are fabricated using selective laser melting, then customization capability is improved, but surface finish and resolution deteriorate
Solution Approach 1:
The patent replaces selective laser melting (SLM) technology with digital light processing (DLP) additive manufacturing. While SLM uses laser melting of metal powder which limits surface finish and resolution, the DLP system uses digital light projection to cure photopolymerizable ceramic material layer-by-layer, achieving superior surface finish and resolution of less than 50 micrometers without requiring post-processing.
Solution Approach 2:
The invention uses composite materials consisting of photopolymerizable resin mixed with ceramic particles (such as alumina or zirconia). This composite material allows the DLP system to fabricate brackets with both the aesthetic properties of ceramic and the structural integrity required for orthodontic applications, while achieving smooth surface finish and high resolution.
3Ease of manufacture
If traditional orthodontic brackets are used, then ease of manufacture is maintained, but treatment time and errors increase
Solution Approach 1:
The patent implements self-service by enabling orthodontic practitioners to fabricate custom brackets directly in their own offices using the DLP additive manufacturing system. The system allows practitioners to scan patient dentition, design custom brackets, and manufacture them on-demand without needing to send samples to external laboratories, thereby eliminating shipping delays and reducing treatment time while maintaining ease of manufacture through automated digital workflows.
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 the creation of highly accurate, custom ceramic orthodontic brackets with improved manufacturing precision, reducing treatment time and errors, and providing a more aesthetically pleasing solution for patients by allowing for precise bracket placement and customization of bracket design, including color matching and shape options.
Implementation Method 1
a light-polymerizable material is polymerized by illumination on at least one horizontal platform
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.