Dental Restoration Blank Molding With Interface Height Feedback
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Solution Overview
Problem
Existing manufacturing devices for dental restoration parts face challenges in achieving precise control over the interface height between tooth and base materials, leading to inconsistent aesthetic results and requiring extensive rework due to variations in polymerization shrinkage and material tolerances, making them unsuitable for large-scale production.
Innovation Solution
A manufacturing device with a mold and plunger system, equipped with a heating and height measuring device, measures the interface height accurately using a control device to calculate and adjust for variations, enabling precise positioning of the material transition through CAD/CAM technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding without height control is used, then production speed is maintained, but interface height precision deteriorates due to polymerization shrinkage variations and material tolerances
Solution Approach 1:
The patent applies preliminary action by measuring the height of the first material layer immediately after injection molding but before the second material is injected. This early measurement allows the system to compensate for polymerization shrinkage and material variations in subsequent steps, ensuring precise interface height control without adding complex equipment to the basic molding process
Solution Approach 2:
The patent implements feedback control by using a height measuring device to detect the actual height of the first material layer, then feeding this information to a control device that calculates and adjusts the injection parameters for the second material. This closed-loop feedback system compensates for material tolerances and shrinkage variations, achieving precise interface height control while maintaining standard molding equipment
2Manufacturing precision
If over-manufactured metal molds with calculated excess material are used, then interface height precision is improved, but productivity deteriorates due to inability to scale for large-scale production
Solution Approach 1:
The patent replaces the mechanical approach of using over-manufactured metal molds with a measurement and control system. Instead of relying on physically larger molds to accommodate material variations, the system uses height sensors and control algorithms to dynamically adjust the molding process, achieving the same precision benefit without sacrificing production speed or scalability
Solution Approach 2:
The patent changes the control parameter from fixed mold dimensions to dynamic height measurements and injection parameters. By measuring the actual height of the first material layer and adjusting the second material injection accordingly, the system adapts to material variations without requiring oversized molds, enabling both precision and high-volume production
3Manufacturing precision
If filler dosage and material composition are varied to achieve precision, then interface height control is improved, but manufacturing complexity increases due to material formulation variations
Solution Approach 1:
The patent uses feedback control to compensate for material composition variations rather than requiring strict material formulation control. The height measuring device detects variations caused by different filler dosages or material batches, and the control device adjusts the molding parameters accordingly, maintaining precision without complicating material formulation procedures
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 solution allows for significantly reduced tolerance ranges, ensuring consistent aesthetic quality by accurately determining and positioning the material transition, reducing rework and enhancing the finish of dental prostheses.
Implementation Method 1
A heating device is provided for the mold, which is in thermal contact with or arranged in the lid
Implementation Method 2
An injection mold into which materials to be polymerized are poured
Data Source
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AI summary
It is a manufacturing device for producing a blank, in particular one to be polymerized, of a dental restoration component. A mold for receiving the blank material has a base, in particular a cup-shaped or bowl-shaped one, and a punch or, optionally, a cap-shaped lid. An insert with a structure on its underside, a heating device for the mold, and a control device for the manufacturing device are provided. A height measuring device is connected to the control device, which measures the height of a reference surface connected to the punch or lid, relative to the base. Based on this measured height, the control device calculates the height position of the structure.