Dental Abutment Blank Clamping for Angled Screw Channels
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Solution Overview
Problem
Current methods for manufacturing dental abutment blanks with angled screw channels are limited by clamping constraints, leading to increased costs, reduced accuracy, and structural weakness due to thin channel walls, as well as the need for prefabrication of various angles and orientations, which complicates the production of custom-tailored dental prostheses.
Innovation Solution
A dental abutment blank design that allows direct clamping at the abutment-implant connection interface, enabling the machining of screw channels in the same operation as the outer contour, with a channel structure featuring varying widths and tapered sections to facilitate angulated screw channels and improved access for milling, reducing inventory costs and enhancing manufacturing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blank is clamped in the opposite end of the implant connection, then the blank can be held securely during machining, but the screw channel must be prefabricated and a cut off peg remains after machining
Solution Approach 1:
Instead of clamping the blank at the opposite end from the implant connection, the invention clamps the blank directly at the abutment-implant connection interface. This inverted clamping approach allows the screw channel to be machined from the same side, eliminating the need for prefabrication and removing the cut off peg issue.
Solution Approach 2:
The invention extracts the clamping function from the opposite end of the blank and relocates it to the abutment-implant connection interface. This separation allows independent optimization of both clamping stability and screw channel machining accessibility.
2Reliability
If the blank is held with a screw through the abutment-implant connection, then the blank can be secured for machining, but a screw channel must be prefabricated in the blank
Solution Approach 1:
The invention merges the clamping function and the screw channel function into a single integrated structure at the abutment-implant connection interface. The screw channel serves both as the fastening mechanism and as the clamping interface, eliminating the need for separate prefabrication steps.
3Manufacturing precision
If blanks with angled screw channels are mounted by screw to the milling machine, then the screw channels can be machined, but blanks must be prefabricated in large variety of angles and orientations
Solution Approach 1:
The invention makes the screw channel angle adjustable rather than fixed during manufacturing. By clamping the blank at the abutment-implant connection and machining the screw channel from the same side, the channel can be angled at any required orientation without requiring prefabrication of multiple blank variants.
Solution Approach 2:
The invention changes the parameter of screw channel orientation from a fixed prefabricated value to a variable that can be adjusted during machining. This allows the same blank design to accommodate various angles and orientations based on specific patient needs.
4Ease of manufacture
If the channel wall thickness is reduced to allow angulated screw channels, then the screw channels can be machined with better access, but the prosthesis structural strength is weakened
Solution Approach 1:
The invention approaches the screw channel machining from a different spatial dimension by clamping at the abutment-implant connection interface rather than from the opposite end. This dimensional change in clamping location enables better milling access for creating angulated channels while preserving adequate wall thickness through optimized toolpath and approach angles.
Data Source
AI summary
A dental abutment blank is provided with a body having a first end and a second end, a connection section at the first end that is configured to be connected to a dental implant, a first channel having a first longitudinal axis and defining a first opening at the first end, and a second channel having a second longitudinal axis and defining a second opening at or near the second end. The first channel and the second channel intersect at an intersection plane, so that the second channel extends at an angle relative to the first channel. In the wall of the second channel a first recess is provided at an axial position at or close to the intersection plane that enlarges the second channel and that has an angled contour. Methods of manufacturing and clamping a dental abutment blank are also provided.