3D-Printed Dental Aligners With Variable Thickness for Force Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Prior orthodontic appliances with homogeneous and continuous material properties lack control over forces applied to teeth, and existing methods often require separate supplementary devices for tooth repositioning, which can be less effective.
Innovation Solution
The development of orthodontic appliances with variable localized properties, such as heterogeneous thickness, stiffness, and material composition, achieved through direct fabrication techniques, allowing for precise control over force application and integration of features like power arms and counter-force connectors for improved tooth movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If orthodontic appliances use homogeneous and continuous material properties, then manufacturing is simpler, but control over forces applied to teeth is insufficient
Solution Approach 1:
The patent applies local quality by creating orthodontic appliances with spatially varying material properties, including heterogeneous thickness distributions and variable stiffness regions. Different portions of the appliance have tailored mechanical properties to provide precise control over force application to specific teeth, resolving the contradiction between manufacturing simplicity and force control precision.
Solution Approach 2:
The patent utilizes composite materials by combining regions of different materials or material densities within a single appliance structure. This allows integration of multiple material properties in one component, enabling both simplified manufacturing through single-piece construction and precise force control through varied material characteristics in different regions.
2Manufacturing precision
If orthodontic appliances use variable localized properties, then control over force application is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functional features into a single integrated appliance structure. Power arms, counter-force connectors, and tooth-repositioning elements are combined into one monolithic or multi-material component, reducing the number of separate parts while maintaining complex force control capabilities. This resolves the contradiction by achieving precise force control without proportionally increasing overall device complexity.
Solution Approach 2:
The patent creates appliances with multi-functionality where single components perform multiple roles. The appliance simultaneously provides tooth repositioning, force application, counter-force balancing, and structural support through integrated features, reducing the need for multiple separate devices while maintaining sophisticated force control.
3Ease of manufacture
If traditional fabrication methods are used, then manufacturing process is simpler, but complex geometries and force distributions are difficult to achieve
Solution Approach 1:
The patent employs parameter changes by utilizing advanced fabrication techniques that enable continuous variation of geometric and material parameters throughout the appliance structure. This includes varying thickness, density, and material composition as continuous functions of position, allowing complex geometries and force distributions to be achieved while maintaining manufacturing feasibility through digital design and additive or multi-material fabrication processes.
Data Source
AI summary
Methods and systems for digitally designing a plurality of aligners are provided. In some embodiments, a method includes receiving an intraoral scan of the patient's teeth, and generating 3D dental model of the patient's teeth using the intraoral scan. The method can include identifying a movement path to move the patient's teeth from an initial arrangement toward a target arrangement through a plurality of intermediate arrangements in accordance with a treatment plan. The method can also include identifying one or more appliance features of at least one aligner, the one or more appliance features including one or more feature regions having one or more feature thicknesses. The method can further include instructing an additive manufacturing machine to directly fabricate the at least one aligner in a layer-by-layer fashion.