3D Printed Dental Part with Oriented Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dental prosthetics and reinforcements fail to adequately match individual users' unique mechanical stress requirements and dimensional constraints, as conventional methods either compromise fiber strength or only adjust shape without ensuring mechanical performance.
Innovation Solution
A method involving 3D printing of resin patterns with strategically oriented fibers, where each layer of fibers is polymerized to form a composite dental part that aligns with specific mechanical stresses, using a robot-controlled system to deposit and polymerize fibers according to detailed data sets defining the part's dimensions and mechanical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a bulk part is machined to achieve the required three-dimensional shape, then the shape of the prosthesis is adjusted to match the user's requirements, but the fibres are cut during machining which compromises the strength and polishability of the prosthesis
Solution Approach 1:
The fibres are arranged in their final orientation within the mold cavity before the resin is injected and cured. This preliminary arrangement ensures that the fibres are not subjected to cutting or damaging operations during subsequent shaping, as the prosthesis is formed by curing the resin-fibre composite in its final shape rather than by machining a bulk part.
2Shape
If a reinforcement is deformed to match the area on which the prosthesis is to be fitted, then the shape can be adjusted, but the fibres are deformed which modifies the mechanical behaviour of the reinforcement
Solution Approach 1:
The fibres are arranged in their final oriented configuration within the mold cavity before resin injection and curing. This preliminary arrangement eliminates the need to deform pre-formed reinforcements, as the fibres are positioned in their stress-aligned orientations during the molding process itself, preserving their mechanical properties while achieving the required shape.
3Ease of manufacture
If conventional prosthetic parts are configured to withstand a predefined set of stresses, then manufacturing is simplified, but the parts cannot adjust to individual user's unique mechanical stress requirements
Solution Approach 1:
The fiber orientation in each region of the prosthesis is specifically tailored to match the local stress patterns of that area. Different regions of the mold cavity can have different fiber orientation patterns, allowing each local zone to be optimized for its specific mechanical demands while maintaining overall structural integrity.
Solution Approach 2:
The data set containing information about user-specific stress patterns is used in advance to configure the fiber arrangement in the mold. This preliminary configuration allows the prosthesis to be manufactured with customized mechanical properties matched to the individual user's requirements, rather than using standardized designs.
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 approach enables the creation of tailor-made dental parts with optimized mechanical performance and shape, ensuring better integration and durability by aligning fiber orientation and resin distribution with the user's specific stress profiles.
Implementation Method 1
forming a first pattern made from a first resin by 3D printing by means of the data set
Implementation Method 2
polymerizing the first pattern, second pattern, third pattern and first and second sets of fibres to form the dental part
Data Source
AI summary
A data set representative of a dental part to be fabricated is provided. The data set defines dimensional and mechanical characteristics of the dental part. First and second patterns are made by 3D printing. A first set of fibres is deposited on a top surface of the first pattern before the second pattern is deposited. The first set of fibres includes a plurality of first fibres oriented in a first set of directions by means of the data set. A second set of fibres is deposited on a top surface of the second pattern. The second set of fibres includes a plurality of second fibres oriented in a second set of directions defined by means of the data set. A third pattern is made from a third resin by 3D printing by means of the data set.