Position-Sensitive Coloring of Dental Ceramics via Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques struggle to produce high-quality, aesthetically pleasing, and mechanically stable dental ceramic articles with complex functionalization, such as color gradients and varying biological properties, at an economic scale.
Innovation Solution
A method for additive manufacturing of position-sensitive colored dental ceramic articles involves providing a flowable ceramic component, forming a green body through sequential deposition, applying a coloring substance in a solvent position-sensitively during deposition, heat treating the green body, and sintering to achieve the final ceramic article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to manufacture dental ceramic articles with complex functionalization, then manufacturing flexibility and geometric complexity are improved, but predictability of physical and chemical properties deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the green body with precise geometric control before applying coloring substances and heat treatment. The sequential deposition process allows pre-planning of material layers, and the coloring substance is applied to the green body surface before sintering, ensuring predictable color distribution in the final product. This staged approach with controlled intermediate steps resolves the unpredictability issue while maintaining manufacturing flexibility.
2Manufacturing precision
If manual coloring application is used on dental ceramic articles, then aesthetic appearance is improved, but productivity and scalability deteriorate
Solution Approach 1:
The patent replaces manual mechanical coloring application with an automated system that applies coloring substance to the green body surface through controlled deposition mechanisms. The system uses automated positioning and application devices that can consistently apply coloring substances with precise control over concentration and distribution, eliminating manual labor while maintaining high aesthetic quality and enabling scalable production.
3Ease of manufacture
If conventional coloring techniques are used on dental ceramics, then color application is simplified, but ability to achieve natural-looking color gradients and complex functionalization deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the coloring process into multiple stages: applying coloring substance to the green body surface, performing heat treatment to activate and distribute the coloring agent, and completing sintering. This segmented approach allows controlled gradient formation through sequential steps rather than attempting to achieve complex coloration in a single operation, maintaining process simplicity while enabling precise color gradients.
Solution Approach 2:
The patent utilizes parameter changes by controlling the concentration, distribution, and activation of coloring substances through heat treatment parameters. By adjusting temperature profiles and treatment durations during the heat treatment step, the system achieves precise control over color gradient formation and intensity distribution, transforming simple coloring application into complex functionalization with natural-looking gradients.
4Reliability
If high-quality functionalization is achieved in dental ceramic articles, then aesthetic and mechanical properties are improved, but manufacturing complexity and cost deteriorate
Solution Approach 1:
The patent merges multiple functions into the additive manufacturing process: structural formation, coloring substance application, and heat treatment are integrated into a single manufacturing workflow. The system combines deposition of ceramic material with simultaneous or sequential application of coloring substances, eliminating separate manual coloring steps and reducing overall manufacturing complexity while achieving high-quality functionalization with both aesthetic and mechanical properties.
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 method enables the creation of dental ceramic articles with precise, natural-looking color gradients and high mechanical stability, surpassing the limitations of manual application and existing state-of-the-art dental articles.
Implementation Method 1
forming a green body by sequential deposition of the ceramic component provided in step a) and optionally a support material not intended to be part of the final article
Implementation Method 2
heat treatment or curing of at least a part of the green body surface obtained in step c)
Implementation Method 3
sintering the green body to obtain the ceramic article
Data Source
AI summary
The present invention relates to a method for additive manufacturing of a position sensitive colored ceramic article comprising: a) providing at least one flowable ceramic component; b) forming a green body by sequential deposition of the ceramic component provided in step a) and optionally a support material not intended to be part of the final article; c) position sensitive application of a coloring substance in a solvent to at least a part of the surface of the green body formed in step b), wherein the coloring substance is applied simultaneously to the sequential deposition; d) heat treatment or curing of at least a part of the green body surface obtained in step c); wherein the method steps a)-d) are at least performed once; e) optionally removing the support material from the green body; and f) sintering the green body to obtain the ceramic article; wherein the coloring substance is a dyestuff according to ISO 18451-1:2019(E). In addition, the present invention relates to a system adapted to perform the method and a control data set configured, when implemented in an additive manufacturing system, to cause the system to execute the steps of the inventive method.