Dental Manufacturing Data Verification for Automated Aligner Fabrication
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Solution Overview
Problem
Existing dental mold fabrication systems are inefficient, leading to issues such as non-unique mold identification, structural problems like holes and free-floating island structures, excessive resin usage, and manual errors in cutting and laser marking, which hinder high-volume, automated production of customized dental aligners.
Innovation Solution
A centralized manufacturing system that processes 3D jaw and teeth data to generate automated mold data, cutting paths, and laser marking information, optimizing resin usage and reducing manual errors through automated fabrication processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual methods are used for dental mold fabrication, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The patent replaces manual mechanical operations with automated computer-controlled systems. Specifically, it uses automated mold fabrication systems that generate molds directly from digital dental models, eliminating manual mold-making processes. The system also employs automated cutting and laser marking machines that operate based on computer-generated instructions, thereby increasing productivity while maintaining precision.
Solution Approach 2:
The system enables self-service automation where the manufacturing process automatically generates its own instructions and controls. The computer model of the dentition automatically generates the mold fabrication instructions, which then automatically control the cutting and laser marking processes without requiring manual intervention at each step, thereby提高ing productivity and consistency.
2Manufacturing precision
If automated fabrication processes are implemented, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The patent uses digital copying of the dentition to create accurate molds. A computer model (digital copy) of the patient's dentition is created from impressions or scans, and this digital copy is then used to generate precise manufacturing instructions for molds, aligners, and other dental appliances. This digital copying process ensures high manufacturing precision while automating the fabrication process.
Solution Approach 2:
The system automatically adjusts various manufacturing parameters based on the digital model and treatment plan. The computer-controlled fabrication processes dynamically modify parameters such as cutting depth, laser power, and mold geometry to achieve the precise dimensions and shapes required for each patient-specific appliance, thereby ensuring high manufacturing precision.
3Reliability
If manual cutting and laser marking are used, then equipment complexity is reduced, but manufacturing precision and reliability deteriorate due to manual errors
Solution Approach 1:
The patent replaces manual cutting and laser marking operations with computer-controlled automated systems. The cutting machine and laser marker are programmed to follow precise digital paths generated from the treatment plan, eliminating variability introduced by manual operations. This automation ensures consistent, repeatable results across all fabrication steps while maintaining equipment reliability.
Solution Approach 2:
The system incorporates feedback mechanisms where the computer-controlled fabrication processes continuously monitor and adjust their operations based on real-time data. The system verifies that each cutting and laser marking operation matches the planned parameters, and can make automatic corrections or halt the process if deviations are detected, thereby ensuring high reliability and consistency in fabrication.
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
Enables high-volume, automated production of customized dental aligners with improved structural integrity, reduced resin consumption, and minimized manual errors, enhancing efficiency and precision in mold creation.
Implementation Method 1
Stereolithography is a method that employs an ultraviolet laser to cure a thin layer of liquid plastic into a solid
Data Source
AI summary
Methods for verifying manufacturing data are provided. In some embodiments, a method includes retrieving a fabrication data package including manufacturing data for one or more dental appliances, where the manufacturing data includes one or more treatment stages for repositioning a patient's teeth using the one or more dental appliances. The method can include determining whether there is an error in the manufacturing data of the fabrication data package. In response to a determination that there is an error in the manufacturing data, the method can include requesting a corrected fabrication data package, and transmitting the corrected fabrication data package to at least one fabrication terminal configured to execute a fabrication process for manufacturing the one or more dental appliances.