Dental Aligner Support Removal Using Laser-Cut Interfaces
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Solution Overview
Problem
Existing methods for fabricating dental aligners via additive manufacturing often require supporting structures that can interfere with orthodontic treatment if not properly removed, necessitating an efficient and accurate means to add and remove these structures post-fabrication.
Innovation Solution
A system and method involving a computing system that modifies digital models of dental aligners to include support structures, followed by additive manufacturing and subsequent laser cutting to remove these structures, ensuring precise and efficient removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structures are added to the digital model for additive manufacturing, then the structural integrity of the intraoral device is maintained during manufacturing, but the support structures interfere with orthodontic treatment if not properly removed
Solution Approach 1:
The laser cutting operation is performed immediately after additive manufacturing while the support structures are still attached to the intraoral device. This preliminary action removes the support structures before they can interfere with orthodontic treatment, resolving the contradiction between maintaining structural integrity during manufacturing and eliminating interference for treatment.
Solution Approach 2:
The patent replaces manual mechanical removal of support structures with an automated laser cutting system. The laser precisely cuts the interface between support structures and the intraoral device, eliminating the need for manual intervention and ensuring complete removal without damaging the device, thus preventing interference with orthodontic treatment.
2Ease of manufacture
If manual methods are used to remove support structures, then the process is simple, but manual errors and surface defects occur
Solution Approach 1:
The patent replaces manual mechanical removal with an automated laser cutting system. The laser precisely follows the digital model's interface geometry to cut support structures, eliminating manual errors and surface defects while maintaining process simplicity through automation. The laser's precision ensures accurate removal without damaging the intraoral device surfaces.
Solution Approach 2:
The laser cutting process uses the digital 3D model as a precise template or copy to guide the cutting path. This ensures that the support structures are removed exactly at the intended interfaces without manual error, while the automated nature of the process maintains ease of manufacture through computer-controlled operation.
3Manufacturing precision
If laser cutting is used to remove support structures, then manufacturing precision and surface smoothness are improved, but additional equipment and process complexity are introduced
Solution Approach 1:
The patent merges the additive manufacturing process with laser cutting by performing the cutting operation immediately after printing while the device is still on the build plate. This integration reduces the need for separate handling and positioning steps, minimizing the increase in system complexity while achieving high manufacturing precision through the laser's accurate cutting capability.
4Object-affected harmful factors
If support structures are removed immediately after manufacturing, then interference with orthodontic treatment is minimized, but the intraoral device must be handled and repositioned
Solution Approach 1:
The patent combines the support structure removal operation with the existing manufacturing process by performing laser cutting immediately after additive manufacturing while the device remains on the build plate. This eliminates the need for separate handling and repositioning steps, minimizing interference with orthodontic treatment without increasing device complexity.
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
Enables repeatable and accurate fabrication of dental aligners with minimized interference, reducing manual errors and surface defects, and improving the structural integrity and smoothness of the final product.
Implementation Method 1
cutting, by the laser system, an interface between the support structures and the dental aligner to remove the support structures from the dental aligner
Data Source
AI summary
Systems and methods for fabricating a dental aligner are provided. The system includes a computing system to receive and prepare a digital model of a dental aligner by adding one or more support structures to the digital model. The system includes a fabrication system to manufacture the dental aligner with the one or more support structures. The system includes a laser system to receive the fabricated dental aligner, orient the dental aligner relative to the laser system, and laser cut an interface between the support structures and the dental aligner to remove the one or more support structures from the dental aligner.