Dental Aligner Cut Line Markings for Precise Manual Trimming
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Solution Overview
Problem
Smaller production facilities lack the expensive and large computer-controlled trimming machines needed to accurately trim orthodontic aligners, leading to potential compromise in appliance efficacy and patient comfort due to manual trimming methods that may not adhere to optimal cut lines.
Innovation Solution
Embedding cut line information into digital models of molds and shells using computer-aided drafting and manufacturing systems, enabling smaller facilities to manufacture aligners with precise markings that guide manual or computer-controlled trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If computer-controlled trimming machines are used to accurately trim orthodontic aligners, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces cut line markings as an intermediary element that transfers trimming information from the digital model to the physical aligner. These markings serve as a mediator between the computer-controlled design phase and the manual or machine trimming phase, enabling smaller facilities to achieve precise trimming without requiring complex computer-controlled equipment. The markings are imprinted on the aligner surface and provide visual guidance for accurate cutting.
Solution Approach 2:
The patent replaces complex computer-controlled mechanical trimming systems with simpler manual or semi-automatic trimming methods guided by visual markings. Instead of relying on expensive 4-axis or 5-axis computer-controlled mills or laser trimmers, the invention enables use of more accessible tools such as manual cutters or simpler machine equipment, reducing the mechanical complexity requirement while maintaining trimming accuracy through the marking guidance.
2Device complexity
If manual trimming methods are used in smaller facilities, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies preliminary action by embedding cut line markings into the aligner during the thermoforming process, before the trimming step. The digital model is prepared in advance with cut line information, and this information is transferred to the physical aligner through the mold features or direct imprinting. This preliminary embedding of trimming guidance ensures that when manual trimming occurs, the operator has precise visual guidance already in place, eliminating the need for complex equipment to provide the precision.
3Device complexity
If cut line information is not transferred to molds or aligners, then device complexity is reduced, but loss of information occurs
Solution Approach 1:
The patent uses the mold as an intermediary carrier for cut line information. Features are incorporated into the mold that will transfer the cut line markings to the aligner during thermoforming. This intermediary mechanism ensures that the digital cut line information from the CAD model is faithfully transmitted through the manufacturing process to the final aligner product, preventing information loss without requiring complex data transfer systems.
Solution Approach 2:
The patent creates a physical copy of the cut line information on the aligner surface through the mold features. The digital cut line data is converted into a physical marking pattern that is imprinted on the aligner during forming. This copying process ensures that the precise geometric information about cut lines is replicated on the final product, maintaining information integrity while using simple thermoforming technology.
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
Ensures accurate trimming of orthodontic aligners, enhancing their fit and functionality while maintaining patient comfort by providing clear markings for manual or machine-assisted cutting.
Implementation Method 1
the shell is formed over the mold using thermoforming equipment
Implementation Method 2
mold having cut line features that imprint a material thermoformed over the mold with cut line markings
Data Source
AI summary
A method of fabricating a dental appliance includes receiving a digital three-dimensional model of a mold for a dental arch of a patient, the digital three-dimensional model of the mold comprising one or more features associated with a cut line. The method further includes fabricating the mold by a rapid prototyping machine using the digital three-dimensional model, the mold having the one or more features. The method further includes thermoforming the dental appliance over the mold, wherein the one or more features cause the dental appliance to have one or more markings or elements for the cut line. The method further includes removing the dental appliance from the mold, and trimming the dental appliance along the cut line using the one or more markings or elements.