Dental Blank With Prefabricated Partial End Surface
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Solution Overview
Problem
Current dental prosthetic manufacturing methods require a large range of prefabricated teeth to accommodate various shapes and colors, leading to high technical effort and inefficiency, with limited adaptation to individual anatomical situations and aesthetic requirements.
Innovation Solution
A blank with a prefabricated partial end surface that corresponds to aesthetically relevant areas, allowing for machining of oversized surfaces to fit individual anatomical shapes, using basic geometric shapes like cones or cylinders, and incorporating a translucency layer for natural-like appearance, reducing the need for multiple blanks and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large range of prefabricated teeth is used to accommodate various shapes and colors, then aesthetic quality and anatomical fit are improved, but device complexity and manufacturing effort increase
Solution Approach 1:
The tooth blank is divided into two functional zones: a prefabricated partial end surface (aesthetic zone) that requires minimal processing, and an oversized surface (anatomical adaptation zone) that is machined to fit the specific patient's anatomy. This segmentation allows the same blank design to serve multiple aesthetic purposes while accommodating individual anatomical variations through selective machining.
Solution Approach 2:
The partial end surface is prefabricated in advance with the correct aesthetic geometry and surface quality before the actual dental prosthesis production. This preliminary action eliminates the need for extensive post-processing of aesthetic surfaces, reducing both manufacturing complexity and the number of required blank variations.
2Manufacturing precision
If complete prefabrication of dentures is performed, then manufacturing precision is improved, but productivity decreases due to time-consuming processes
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: (1) prefabrication of the aesthetic partial end surface which is done once for a family of blanks, and (2) selective machining of the anatomical adaptation zone for each individual patient. This segmentation eliminates redundant processing of aesthetic surfaces and focuses manufacturing effort only where customization is needed.
Solution Approach 2:
The blank is deliberately designed with an oversized surface that extends beyond the final anatomical boundaries. This excessive material is then selectively removed through machining to achieve the precise anatomical fit. The oversized design ensures that the aesthetic partial end surface is never compromised during machining, while providing sufficient material for accurate anatomical adaptation.
3Difficulty of detecting and measuring
If position control is performed only upon contact with material, then measurement simplicity is maintained, but manufacturing precision deteriorates due to limited control timing
Solution Approach 1:
The oversized surface provides a preliminary reference zone that allows position control and calibration to be performed before the machining tool approaches the final anatomical boundaries. This preliminary positioning action ensures that subsequent machining operations are accurately aligned, improving position accuracy without requiring complex real-time measurement systems.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The invention relates to a method, a blank, an assortment of blanks, a dental database and a blank database for producing a partial denture. The method comprises the provision of a 3D model of a partial denture and the selection of a suitable blank from a plurality of possible blanks. An esthetically relevant partial construction surface on the 3D model of the partial denture is determined as a part of an outer surface of the partial denture. A blank is selected from a plurality of blanks having a prefabricated esthetically relevant partial end surface of a tooth surface, the partial end surface of said blank corresponding at least approximately to the determined end construction surface. The 3D model of the partial denture is machined out of the selected blank in such a manner that the prefabricated partial end surface of the blank remains unmachined in at least a center area thereof.