Customized Ceramic Orthodontic Brackets via DLP for Precise Tooth Fit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current orthodontic bracket manufacturing techniques lack precision and aesthetics, with no efficient method for creating custom ceramic labial and lingual brackets, leading to inaccuracies and increased treatment time 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 3D CAD models, and producing brackets layer by layer using a DLP machine with high accuracy and precision, allowing for in-office fabrication of ceramic brackets that match individual tooth profiles and orthodontic needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If preformed brackets are used with indirect bonding, then manufacturing complexity is reduced, but manufacturing precision and fit accuracy deteriorate
Solution Approach 1:
The patent applies preliminary action by creating a custom bracket that is pre-adapted to the specific tooth morphology through digital scanning and 3D modeling before fabrication. The bracket is designed with a custom pad that precisely matches the target tooth surface geometry, ensuring optimal fit and contact area before the actual bonding procedure occurs in the clinic.
Solution Approach 2:
The patent utilizes parameter changes by varying the pad geometry, thickness, and surface characteristics of the bracket based on the specific tooth morphology data obtained from digital scanning. The custom bracket design allows for precise adjustment of multiple parameters including pad contour, slot position, and overall bracket shape to achieve optimal fit for each individual tooth.
2Manufacturing precision
If custom metal lingual brackets are fabricated using selective laser melting, then manufacturing precision is improved, but surface finish quality deteriorates
Solution Approach 1:
The patent applies parameter changes by selecting different material states and processing parameters - using a photopolymerizable ceramic slurry instead of metal powder, and employing light-based curing instead of thermal melting. This fundamentally changes the fabrication parameters to achieve both high precision and superior surface finish simultaneously.
Solution Approach 2:
The patent uses composite materials by combining ceramic particles (alumina or zirconia) suspended in a photopolymerizable resin matrix. This composite approach allows the material to be precisely deposited and cured layer-by-layer, achieving both accurate geometry and smooth surface finish that would be difficult to obtain with pure metal SLM processing.
3Ease of manufacture
If standard non-custom brackets are used with custom wire bends, then ease of manufacture is maintained, but manufacturing precision and aesthetic quality deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-positioning the bracket slot at the exact desired location and orientation through custom 3D modeling and fabrication. The slot is created in the correct position relative to the tooth surface during the bracket manufacturing process itself, eliminating the need for subsequent wire bending adjustments to compensate for misalignment.
Solution Approach 2:
The patent inverts the traditional approach by customizing the bracket itself rather than customizing the wire. Instead of using a standard bracket and bending the wire to achieve proper tooth positioning, the patent creates a custom bracket with a custom pad that directly adapts to the tooth morphology, with the slot pre-positioned at the ideal location.
4Manufacturing precision
If DLP additive manufacturing is used for ceramic brackets, then manufacturing precision and customization are improved, but device complexity and initial manufacturing cost increase
Solution Approach 1:
The patent applies universality by using a DLP machine that can fabricate multiple types of orthodontic components - not just custom labial brackets but also custom lingual brackets, archwires, and other orthodontic appliances. This multi-functionality justifies the investment in the sophisticated DLP equipment by enabling a range of customized products from a single device.
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 production of highly accurate, aesthetically pleasing, and custom-fit ceramic orthodontic brackets with improved manufacturing accuracy, reducing treatment time and errors, and allowing for in-office fabrication, thus enhancing patient outcomes and practice efficiency.
Implementation Method 1
digital light processing (DLP) additive manufacturing method for creating 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.