Customized Orthodontic Bracket via Selective Laser Melting
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Solution Overview
Problem
Current orthodontic brackets are either off-the-shelf products that do not fit individual clinical situations well or are customized and costly, lacking in ease of placement and durability during orthodontic treatments.
Innovation Solution
A method for creating customized orthodontic brackets with a bracket base and archwire slot, where the bracket body and head are shaped to match the patient's tooth, using 3D modeling and manufacturing techniques like Selective Laser Melting to minimize thickness and enhance comfort, with a ligating portion for easy archwire attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If off-the-shelf brackets are used, then manufacturing costs are minimized, but the brackets do not fit individual clinical situations well and placement precision deteriorates
Solution Approach 1:
The method performs preliminary digital planning and design of the bracket before manufacturing. A digital model of the patient's dentition is created, and the bracket position and orientation are predetermined based on the desired final tooth alignment. This preliminary action allows custom brackets to be manufactured with precise specifications for each patient, resolving the contradiction between low manufacturing cost and high placement precision.
Solution Approach 2:
The invention changes the parameters of the bracket design based on individual patient needs. The bracket's position, orientation, and dimensions are adjusted according to the specific clinical situation and tooth morphology. This parameter customization enables precise fit and placement while maintaining cost-effectiveness through standardized manufacturing processes applied to customized designs.
2Manufacturing precision
If customized brackets are made to fit individual clinical situations, then placement precision is improved, but manufacturing costs and application costs increase
Solution Approach 1:
The invention replaces traditional mechanical manufacturing methods with digital design and automated manufacturing processes. A digital workflow is implemented where the bracket design is created using software based on patient-specific data, then manufactured using precise automated systems. This substitution reduces manual intervention and associated costs while maintaining high placement precision.
Solution Approach 2:
The invention creates a universal digital platform that can generate customized bracket designs for different patients using the same manufacturing process. The digital design system serves multiple functions: creating patient-specific models, determining optimal bracket positions, and generating manufacturing files. This multi-functionality reduces overall costs while maintaining customization and precision.
3Ease of operation
If bracket thickness is minimized for comfort, then patient comfort and adaptability are improved, but structural durability may deteriorate
Solution Approach 1:
The invention applies local quality by varying the bracket thickness and material properties in different regions. The bracket design incorporates thicker sections in areas requiring high strength and durability, while maintaining thinner sections in areas where patient comfort is paramount. This localized differentiation resolves the contradiction between comfort and durability by optimizing each region for its specific functional requirements.
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
The method provides customized brackets that are comfortable, easy to adapt to, and durable, reducing the time for patient adjustment and allowing for precise placement with minimized archwire variations throughout treatment.
Implementation Method 1
providing computer processable data for the bracket and using the data to manufacture the bracket in one piece by an automated manufacturing process such as by Selective Laser Melting
Data Source
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AI summary
A method of making a customized orthodontic bracket (20) which comprises a bracket base for attaching the bracket (20) at a patient's tooth (200), a bracket body with a bracket head, and an archwire slot. According to the method a three-dimensional tooth model representing the shape of at least part of a patient's tooth (200) is provided. A bracket receiving area is determined on the tooth model, and the bracket base is provided with a tooth-facing surface that is shaped according to the shape of the bracket receiving area. Further an outline of the bracket head is determined on the tooth model, and the bracket head is provided with a bracket head surface (26a, 26a') that is shaped according to the shape within the bracket head outline. Thus a bracket (20) is provided which has an outer tongue-facing or cheek-facing surface of a shape corresponding to the natural shape of the tooth the bracket is attached to. The disclosure helps minimizing any discomfort during an orthodontic treatment with the brackets.