Dental Laser Cutting Control for Thickness-Dependent Edge Brittleness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser cutting systems face issues such as material discoloration, brittleness, and unintended cutting into support materials, especially when cutting at high speeds or with varying material thicknesses, leading to reduced effectiveness and undesirable material characteristics.
Innovation Solution
A system and method that adjusts laser energy, optical components, and fixture movement to maintain a predetermined ratio of laser energy to material thickness, ensuring precise cutting without damaging the support material, using a control mechanism to manage laser power, optical adjustments, and fixture speed in multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high energy laser beam is used to cut through material quickly, then cutting speed is improved, but material becomes more brittle and characteristics are altered
Solution Approach 1:
The system dynamically adjusts laser beam parameters (energy, focal length) and cutting speed based on real-time material thickness feedback. The control mechanism continuously modifies operating conditions to maintain optimal cutting parameters, allowing high-speed cutting while preventing excessive heat input that causes brittleness
Solution Approach 2:
The patent changes physical parameters of the laser beam (energy level, focal length) and cutting process (speed, passes) based on material thickness. By adjusting these parameters dynamically, the system achieves both high cutting speed and maintains material characteristics, resolving the contradiction between productivity and material stability
2Manufacturing precision
If laser cuts through thicker material portions, then cutting effectiveness is reduced, but using higher energy may damage thinner portions or cut into support material
Solution Approach 1:
The system performs preliminary scanning or measurement of material thickness before cutting, and pre-calculates the appropriate laser parameters. This preliminary action allows the control mechanism to set optimal cutting parameters in advance, ensuring effective cutting through thick material without excessive energy that could damage support material
Solution Approach 2:
The laser cutting parameters are localized to match the specific thickness at each cutting position. The system adjusts energy and speed locally based on real-time thickness feedback, providing effective cutting where needed while applying reduced energy in areas where support material protection is critical
3Reliability
If fixed laser parameters are used for calibration, then cutting consistency is improved, but adaptability to varying material thickness is reduced
Solution Approach 1:
The system transitions from fixed to dynamic parameters. The control mechanism continuously adjusts laser energy, focal length, and cutting speed based on real-time material thickness measurements, maintaining cutting consistency across varying thicknesses while adapting to each specific condition
Solution Approach 2:
The system implements feedback control by measuring actual material thickness during cutting and using this information to adjust laser parameters. This closed-loop feedback maintains cutting consistency while providing adaptability to thickness variations, resolving the contradiction between reliability and versatility
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 efficient cutting through materials of varying thicknesses without altering their characteristics or cutting into support materials, maintaining material integrity and reducing post-cut polishing needs.
Implementation Method 1
a laser generating component for producing a laser beam
Implementation Method 2
the laser beam vaporizes material at a cut path
Data Source
AI summary
Laser cutting systems and methods are described herein. Systems may include a laser, an optical component, a fixture for holding a dental appliance, and a controller. A cut path for trimming excess material from the dental appliance may be derived from a virtual cut path in a virtual version of the dental appliance. The excess material may be trimmed from the dental appliance along the cut path with the laser while adjusting a laser energy applied to the dental appliance to reduce a brittleness at an edge of the cut path. Adjusting the applied laser energy may include adjusting one or more of: a power of the laser, an optical component of the laser to adjust a focal length of the laser, and a relative orientation of the laser with respect to the dental appliance in at least three axes of movement.