3D-Printed Dental Appliance With Integral Arch Expander Force Control
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Solution Overview
Problem
Existing orthodontic appliances often lack sufficient control over the forces applied to teeth, and the use of power arms can be less than ideal, particularly in achieving precise tooth movement and torque application.
Innovation Solution
Orthodontic appliances with variable localized properties, such as heterogeneous thickness, stiffness, and material composition, are produced through direct fabrication techniques, allowing for complex geometries and improved force control. Integrally formed features, including power arms and connecting structures, are directly fabricated to enhance tooth movement precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If homogeneous and continuous material properties are used in orthodontic appliances, 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 varying material compositions across different regions of the appliance. This allows different portions of the appliance to exert different forces on different teeth, providing precise control over force application while maintaining a single integrated structure.
2Manufacturing precision
If power arms are used to apply torque to teeth, then tooth movement control is improved, but the use and placement of power arms becomes less than ideal
Solution Approach 1:
The patent merges the power arm functionality directly into the orthodontic appliance structure, creating an integrally formed appliance that eliminates separate power arm components. This integration simplifies placement and operation while maintaining precise torque application capabilities through the appliance's built-in geometric features and force application structures.
3Manufacturing precision
If complex geometries are fabricated using traditional methods, then manufacturing precision is limited, but fabrication complexity increases
Solution Approach 1:
The patent employs additive manufacturing technology that enables precise control over geometric parameters during fabrication. This allows the creation of complex three-dimensional geometries with high precision, including varying thickness profiles and integrated features, while simplifying the manufacturing process compared to traditional methods that would require multiple assembly steps.
Data Source
AI summary
Systems and methods for fabricating dental appliances are provided. In some embodiments, a method includes determining an appliance geometry for a dental appliance, where the appliance geometry includes a first region representing a first shell portion having a first set of cavities configured to receive one or more first teeth at a first side of a dental arch of a patient, a second region representing a second shell portion having a second set of cavities configured to receive one or more second teeth at a second side of the dental arch, and a third region representing an integrally formed arch expander configured to exert forces to increase a width of the dental arch. The method can also include generating instructions for fabricating the dental appliance having the appliance geometry via an additive manufacturing process, and using the instructions to instruct a fabrication system to fabricate the dental appliance.