Additive Mold Base for Custom Wax Dental Occlusion Rims
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Solution Overview
Problem
Conventional dental impression methods using wax are unable to be additively manufactured due to their low melting point, making it difficult to design a bespoke insert that ensures accurate occlusion without adding extra steps to the denture manufacturing process.
Innovation Solution
Additively manufacture a bespoke base and top that fit snugly within a patient's mouth, defining a U-shaped slot, and fill it with liquid wax to create a custom-fit insert that aligns with the patient's tooth-line, using materials with a higher melting point than wax.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wax is used for dental impressions, then the impression material is soft and easy to bite, but it cannot be additively manufactured due to low melting point
Solution Approach 1:
The invention divides the dental impression system into two separate components: a permanently retainable base (additively manufactured) and a wax rim (traditional material). The base serves as the structural foundation that can be custom-fitted through additive manufacturing, while the wax rim provides the impression-taking function. This segmentation allows each component to be optimized for its specific requirements without compromise.
Solution Approach 2:
The additively manufactured base acts as an intermediary carrier that holds and positions the wax rim. The base includes features like a wax rim receiving portion and retention features that secure the wax in place. This intermediary structure enables the combination of modern manufacturing techniques with traditional materials, solving the contradiction between manufacturability and material properties.
2Manufacturing precision
If a custom-fit insert is created to ensure accurate occlusion, then dental impression accuracy improves, but the manufacturing process becomes more complex
Solution Approach 1:
The base is additively manufactured in advance with pre-integrated features including the wax rim receiving portion, retention features, and anatomical contours. This preliminary fabrication of the customized base eliminates the need for complex post-assembly adjustments and simplifies the overall manufacturing process while ensuring precise occlusion accuracy.
Solution Approach 2:
The invention merges multiple functions into a single integrated base structure: anatomical fitting, wax rim retention, and alignment features are all combined in one additively manufactured component. This consolidation reduces device complexity compared to traditional multi-component systems while maintaining high manufacturing precision for occlusion.
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
Ensures accurate dental impressions by reducing the risk of poor occlusion and improving the fit of dentures without additional manufacturing steps.
Implementation Method 1
fill it with liquid wax to create a custom-fit insert
Data Source
AI summary
A method according to the disclosure herein includes producing a mold having a base is based on a digital model of a patient mouth, a first mold portion monolithically formed with the mold base and defining a U-shaped recess, and a second mold portion shaped to correspond the U-shaped recess; aligning the first mold portion and the second mold portion; filling the U-shaped recess with a wax; and removing the second mold portion to result in a wax mold comprising the wax, the mold base, and the first mold portion.