Customized Orthodontic Bracket Structure for Precise Archwire Engagement
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Solution Overview
Problem
Conventional orthodontic brackets face challenges such as manufacturing reproducibility issues, difficulty in engaging archwires, user error in attachment application, and aesthetic concerns, particularly with lingual brackets, leading to reduced treatment efficacy and increased treatment time.
Innovation Solution
The development of integrally formed orthodontic brackets with customized mounting and treatment portions, featuring undercut bonding elements and additive manufacturing, allowing for precise fit with clear aligners and archwires, enhancing manufacturing precision and patient comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional multi-process manufacturing is used for brackets, then production capability is maintained, but manufacturing precision and reproducibility deteriorate
Solution Approach 1:
The patent combines multiple manufacturing processes (molding and stamping/sintering) into a single integral molding process. The bracket body and mounting portion are formed as one piece, eliminating the need to separately manufacture and assemble components, thereby improving slot size consistency and reducing production complexity.
Solution Approach 2:
The patent changes the manufacturing approach from multi-process assembly to single-process integral molding. This parameter change in the manufacturing method directly improves the reproducibility and precision of critical dimensions like slot size, while maintaining production capability through optimized molding parameters.
2Ease of operation
If traditional lingual brackets are used, then aesthetic reasons are satisfied, but engagement of archwire becomes extremely difficult and time-consuming
Solution Approach 1:
The patent incorporates a preliminary action by pre-forming the archwire engagement features (slots and guiding structures) as integral parts of the bracket during the molding process. This preliminary preparation of the engagement geometry eliminates the need for complex manual manipulation during archwire insertion, making the process easier and faster.
Solution Approach 2:
The patent employs curved and rounded geometries in the archwire engagement features rather than sharp angles. The curved slot paths and rounded transition areas facilitate smoother archwire insertion and reduce friction, thereby easing the engagement operation and reducing the time required.
3Reliability
If clear aligners alone are used, then treatment simplicity is maintained, but alignment efficacy and accuracy deteriorate
Solution Approach 1:
The patent segments the treatment system into two functional components: clear aligners for overall alignment and lingual brackets with archwires for precise final positioning. This segmentation allows each component to perform its specialized function optimally, improving overall alignment accuracy while maintaining treatment simplicity through coordinated use of both systems.
Solution Approach 2:
The patent creates a multi-functional treatment system where lingual brackets serve dual purposes: providing anchorage points for archwires and serving as precise positioning elements for clear aligners. This multi-functionality enhances alignment accuracy while avoiding the need for separate specialized components, thereby maintaining treatment simplicity.
4Measurement precision
If composite attachments for clear aligners are applied manually, then application flexibility is maintained, but user error increases and fit accuracy deteriorates
Solution Approach 1:
The patent uses precision-molded复制 (copies) of the ideal bracket geometry directly from digital designs. The integral molding process creates exact reproductions of the designed bracket geometry, eliminating the variability introduced by manual composite attachment application. This copying approach ensures consistent, high-precision fit while simplifying the application process.
Solution Approach 2:
The patent replaces the manual mechanical application process of composite attachments with a precision molding process. Instead of manually shaping and bonding composites, the bracket is formed as a precise mold copy, substituting manual dexterity with controlled manufacturing processes that ensure consistent, high-precision geometry and fit.
Data Source
AI summary
Orthodontic brackets are disclosed. An orthodontic bracket is formed such that the body and mesh portions are formed integrally in one piece, and the tooth-side mounting surface includes bonding elements that have an undercut angle to the mounting surface. The bonding elements can further include geometry to facilitate the spreading of bonding material. In some aspects, the bracket can also comprise elements for wire-mounting and aligner tray interaction. A system and methods of treatment are further disclosed. The bracket can be customized for an individual patient.