Customized Bite Opening Devices via Additive Fabrication
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Solution Overview
Problem
Conventional bite opening devices (BODs) face challenges in achieving accurate and strong attachment to teeth due to issues with mold overfilling or underfilling, leading to flash, improper adhesion, and time-consuming manual placement, which can result in errors and inadequate occlusion management.
Innovation Solution
A computer-implemented method for generating 3D models for additive fabrication of customized BODs, involving the creation of retentive structures and a bonding tray tailored to a patient's tooth anatomy, using additive manufacturing techniques to produce BODs with specific hardness properties and retentive designs for enhanced bonding and ease of attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mold-based fabrication is used for BODs, then manufacturing process is simple, but manufacturing precision is poor due to overfilling or underfilling issues
Solution Approach 1:
The patent replaces the conventional mechanical mold-based fabrication system with an additive manufacturing system. This substitution eliminates the overfilling/underfilling issues inherent in mold-based methods by building the BOD layer-by-layer with precise material deposition, achieving superior attachment accuracy while accepting increased fabrication process complexity
Solution Approach 2:
The patent changes the fundamental fabrication parameter from mold-based material injection to additive layer-by-layer construction. This parameter change enables precise control over material placement and BOD geometry, directly improving attachment accuracy by eliminating the dimensional tolerances and flash issues associated with conventional molding
2Productivity
If manual placement of BODs is used, then ease of operation is maintained, but productivity is low and errors increase
Solution Approach 1:
The patent implements self-service through the bonding tray design that guides BOD placement automatically. The tray's geometry and the BOD's retentive structures work together to enable self-alignment and self-positioning during attachment, increasing productivity while maintaining ease of operation by eliminating complex manual positioning procedures
Solution Approach 2:
The bonding tray serves as an intermediary tool between the operator and the teeth. It provides a structured interface that simplifies the placement process by pre-positioning BODs in correct orientations and locations, thereby increasing productivity without compromising operational simplicity for the clinician
3Adaptability or versatility
If generic BOD designs are used, then device complexity is low, but adaptability is poor for individual patient anatomy
Solution Approach 1:
The patent applies local quality by creating patient-specific BOD designs that match the unique anatomy of each patient's teeth. The additive manufacturing process enables local adaptation of BOD geometry to specific anatomical features, achieving superior adaptability while the digital workflow manages the complexity of customization automatically
Solution Approach 2:
The patent implements preliminary action by creating digital 3D models of patient anatomy before fabrication. This preliminary digital planning and modeling phase allows for optimal BOD design adaptation to individual anatomy, improving adaptability while the pre-planned digital approach streamlines the overall customization process
4Strength
If retentive structures are added to BODs, then strength of attachment is improved, but device complexity increases
Solution Approach 1:
The patent incorporates retentive structures that create a porous or textured surface geometry on the BOD. This porous-like structure increases surface area and mechanical interlocking capability, significantly improving bonding strength. The additive manufacturing process creates these complex porous structures directly without additional manufacturing steps, managing device complexity through digital fabrication
Data Source
AI summary
Techniques are described for fabricating bite opening devices (BODs) that are customized to a patient's teeth and that can be accurately and strongly attached. The techniques include designing, and producing via additive fabrication, a bonding tray and a BOD that are contoured to match the patient's tooth anatomy. The BOD may be inserted into a cavity in the bonding tray, wherein the surface of the BOD and the bonding tray may match the tooth anatomy so that the tray and BOD can be guided to the proper location in the mouth, and so that the surface of the BOD matches the surface to which it will be attached. An adhesive may be applied to the surface of the BOD and cured to attach the BOD to the tooth. As a result, proper BOD placement is provided with a desired adhesion between the BOD and the tooth.