Custom Dental Aligner Mold Fabrication for High-Volume Automation
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Solution Overview
Problem
Existing dental mold manufacturing processes are inefficient, leading to issues such as non-unique mold identification, structural problems, excessive resin use, and manual errors in cutting and laser marking, which hinder high-volume, automated production of customized dental aligners.
Innovation Solution
A system and method for automated fabrication that includes a central manufacturing terminal and remote terminals, processing data packages for customized items, verifying data accuracy, generating 3D mold data, cutting paths, and laser marking data to optimize resin usage and minimize manual errors, while enabling efficient tray packing and high-volume production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual dental mold manufacturing methods are used, then flexibility in customization is maintained, but productivity and manufacturing precision deteriorate due to manual errors and inefficiency
Solution Approach 1:
The patent replaces manual mechanical mold-making processes with an automated computer-controlled system. The system uses digital imaging to capture dental impressions, processes them through software to generate unique mold data, and controls automated equipment to fabricate molds. This substitution eliminates manual errors in mold identification and significantly increases production volume while maintaining or improving precision.
2Productivity
If rapid prototyping methods are used to produce multiple molds from a computerized model, then productivity improves, but device complexity increases due to the need for specialized equipment and software
Solution Approach 1:
The patent creates a multi-functional integrated system that combines digital imaging, data processing, mold design, and automated fabrication capabilities within a single platform. The system can handle multiple tooth arrangements, generate various types of dental molds, and produce multiple copies from a single digital model. This universality justifies the initial complexity investment by enabling high-volume production across different dental applications.
3Manufacturing precision
If automated fabrication systems are implemented, then manufacturing precision and productivity improve, but ease of manufacture worsens due to the complexity of implementing and maintaining the system
Solution Approach 1:
The automated system is designed to be self-sufficient in many aspects of the manufacturing process. Once the digital dental impression is captured, the system automatically processes the data, generates the mold design, and controls the fabrication equipment without requiring constant manual intervention. The system manages its own operations, reducing the need for specialized operators and simplifying implementation despite the advanced technology involved.
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 approach enables high-volume, automated production of customized dental aligners with improved structural integrity, reduced resin usage, and minimized manual errors, enhancing efficiency and precision in mold manufacturing.
Implementation Method 1
Stereolithography is a method that employs an ultraviolet laser to cure a thin layer of liquid plastic into a solid
Implementation Method 2
As each layer is laid down, a laser beam passes over the edges of the part, detailing the part and separating the part from the excess material
Data Source
AI summary
Method and system for providing volume manufacturing of customizable items including receiving a data package including a plurality of manufacturing parameters, each of the plurality of manufacturing parameters associated with a unique item, verifying the received data package, and implementing a manufacturing process associated with the received data package is provided.