3D Printed Retention Layer for Dental Crown Coating Adhesion

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Solution Overview

Problem

Stainless-steel dental crowns have an unattractive appearance and existing esthetic coatings tend to delaminate or shear off due to occlusal forces, exposing the metal layer and compromising the natural look.

Innovation Solution

A dental crown with a three-dimensionally printed metal coating retention layer that securely adheres a polymeric esthetic coating, using diffusion bonding or other processes to create a strong, flexible, and durable laminate structure that withstands mechanical forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If an esthetic coating is applied to a stainless-steel dental crown, then the appearance becomes more natural and tooth-like, but the coating tends to delaminate or shear off due to occlusal forces

Engineering Contradiction:

Improveesthetic appearanceVSAvoidcoating retention

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The invention divides the crown structure into distinct functional layers: a stainless-steel base layer for durability, an intermediate retention layer with microporous structure for coating adhesion, and an outer esthetic coating layer for natural appearance. This segmentation allows each layer to optimize its specific function while working together as a unified structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs a composite material structure combining stainless steel with a polymer-based retention layer and esthetic coating. The composite construction integrates the mechanical strength of metal with the adhesive and aesthetic properties of polymers, creating a multi-functional restoration that resolves the contradiction between appearance and durability.

Inventive Principle:

Principle #40Composite materials

2Strength

If a traditional metal layer structure is used, then the crown is durable, but the esthetic coating cannot adhere properly and delaminates under mechanical forces

Engineering Contradiction:

Improvestructural durabilityVSAvoidcoating adhesion

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The retention layer exhibits local quality variations with its microporous structure, where the pore distribution and density are optimized specifically at the interface between the metal base layer and the esthetic coating. This localized structural feature enhances coating adhesion without compromising the overall structural durability of the crown.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The retention layer acts as an intermediary between the stainless-steel base layer and the esthetic coating. Its microporous structure provides mechanical interlocking and surface area for bonding, mediating the interface between the metal substrate and the polymer coating to ensure proper adhesion while maintaining structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the crown structure is simplified, then manufacturing is easier, but the coating retention and long-term durability are compromised

Engineering Contradiction:

Improvestructural simplicityVSAvoidcoating longevity

Core Design Contradiction:

Device complexityVSDuration of action of stationary object

Solution Approach 1:

The retention layer with its pre-formed microporous structure is created before applying the esthetic coating. This preliminary structural preparation provides built-in adhesion mechanisms that ensure long-term coating retention without requiring complex post-application modifications or additional bonding steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The retention layer utilizes a microporous material structure where the controlled porosity provides mechanical interlocking for the esthetic coating. This porous architecture enhances coating longevity through physical anchoring while maintaining a relatively simple overall crown structure that is manufacturable using conventional techniques.

Inventive Principle:

Principle #31Porous materials

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

The solution provides a long-lasting, aesthetically pleasing dental crown that maintains its esthetic coating even under occlusal forces, ensuring a natural tooth-like appearance and durability.

Implementation Method 1

using diffusion bonding or other processes to create a strong, flexible, and durable laminate structure

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Data Source

PatentEP3890648B1Dental crown having a three-dimensional printed highly retentive layer and methods of making the same

Publication Date: 2023.05.10 SOLVENTUM INTELLECTUAL PROPERTIES CO

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AI summary

Three-dimensional printed dental crowns and methods of making the same. The dental crown may include one or more three-dimensional printed parts and is formed into a shell shaped to cover a portion of a tooth of a patient; a three-dimensionally printed coating retention layer that comprises a plurality of interstitial regions; and a composition on the coating retention layer and within the plurality of the interstitial regions to bond the coating composition to the shell.