Customized Lingual Brackets via Selective Laser Melting
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Solution Overview
Problem
Current manufacturing methods for lingual orthodontic brackets are standardized, failing to meet individual patient needs, leading to discomfort and inefficiency due to inadequate adaptation to the complex tooth surface and stimulation of the tongue.
Innovation Solution
The direct manufacturing of customized lingual orthodontic brackets using selective laser melting, involving precise measurement of dentition data, 3D CAD modeling, and layer-by-layer production with high accuracy and customizable materials like dental gold and titanium alloys, to create brackets that closely match the tooth surface and minimize twisting errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standardized brackets are used for lingual orthodontics, then manufacturing cost and time are reduced, but adaptability to individual tooth surfaces deteriorates
Solution Approach 1:
A digital 3D model of the patient's tooth surface is created in advance through scanning, allowing customization planning before manufacturing. This preliminary digital preparation enables the subsequent selective laser melting process to produce highly adaptive brackets without requiring complex manual adjustment steps during the manufacturing process itself.
Solution Approach 2:
The manufacturing process transitions from standardized mass production to customized production by changing key parameters including tooth surface geometry data, bracket dimensions, and material properties. The selective laser melting process allows precise control of these parameters to match individual patient anatomy while maintaining manufacturing efficiency through digital workflow.
2Adaptability or versatility
If smaller brackets are used to fit complex tooth surfaces, then adaptability improves, but manufacturing precision requirements worsen
Solution Approach 1:
Traditional mechanical manufacturing methods are replaced with selective laser melting, an additive manufacturing process that uses laser energy to selectively fuse metal powder layer by layer. This substitution enables superior manufacturing precision for small, complex bracket geometries by building them directly from digital 3D models with micrometer-level accuracy, eliminating the limitations of subtractive or formative mechanical processes.
Solution Approach 2:
The manufacturing approach transitions from 2D or 3D subtractive processes to 4D additive manufacturing (3D space plus time/layer accumulation). This dimensional change allows gradual building of complex small-scale bracket structures with precise geometric control at each layer, achieving high fitting accuracy on complex tooth surfaces that would be difficult or impossible to obtain through traditional mechanical manufacturing.
3Reliability
If more adhesive is used to fill gaps between bracket and tooth, then bracket stability improves, but risk of detachment worsens due to increased adhesive volume
Solution Approach 1:
The invention applies surface treatment techniques that modify the adhesive interface properties, creating optimal bonding conditions between the bracket and tooth surface. By controlling surface energy and wettability characteristics, the adhesive forms a thin, uniform layer with maximum bonding strength, eliminating the need for thick adhesive applications that would increase detachment risk while maintaining excellent bracket stability.
4Object-affected harmful factors
If lingual brackets are used for orthodontics, then aesthetic appearance and tooth protection improve, but tongue stimulation and discomfort worsen
Solution Approach 1:
The bracket design incorporates locally optimized features including reduced thickness in areas that contact or near the tongue, selective reinforcement only where structurally necessary for orthodontic function, and surface finish variations that minimize irritation. This local quality approach allows the bracket to maintain strength and functionality while reducing tongue stimulation in specific critical areas, resolving the contradiction between protection benefits and discomfort.
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 highly customized, accurately fitting lingual orthodontic brackets that reduce discomfort and enhance treatment efficiency by minimizing adhesive use and optimizing the bracket's interaction with the tooth surface, while reducing manufacturing time and cost.
Implementation Method 1
Selective laser melting technique is an emerging and rapidly maturing prototyping technique and it has been utilized in the medical field. It can be used to directly manufacture lingual brackets which is usually composed of metal materials such as dental gold alloy or titanium alloys.
Implementation Method 2
produce the brackets by laminated manufacturing directly
Data Source
AI summary
This invention has provided a direct manufacturing methodology of customized lingual orthodontic brackets by selective laser melting. The procedure is as follows. First of all, measure the dentition data and construct the 3D CAD model of the teeth through reverse engineering. Then a single soleplate of the lingual bracket contacting the tooth surface, as well as the ideal slot position is designed based on the teeth features. The designed models are later imported into the SLM machine and used to produce the brackets with desired materials directly. This method can actualize customized manufacture with highly accuracy, producing highly matched brackets all at once. The invention not only saves time and cost, but also has wide adaptation range and is able to adopt various raw materials. Different raw materials can be utilized in one step to accommodate specific capacity requirement of different parts of the brackets.