Dental Appliance Laser Smoothing and Auto-Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional dental appliance manufacturing methods using laser cutting result in stress concentration points and discomfort due to sawtooth or ridged profiles, and manual calibration of laser systems is time-consuming and prone to errors, leading to faulty products and increased manufacturing costs.
Innovation Solution
A method involving preliminary laser operations to form a dental appliance and subsequent post-processing laser operations with modified energy output and scanning parameters to smooth the edges, combined with a machine learning model for predictive data to optimize laser operations and automate calibration, reducing stress concentrations and improving product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser cutting is used to manufacture dental appliances, then manufacturing speed and productivity are improved, but the laser lines create sawtooth or ridged profiles that cause stress concentration points and patient discomfort
Solution Approach 1:
The patent applies preliminary laser cutting to quickly form the dental appliance structure, then performs post-processing laser operations to smooth the laser lines. This two-stage approach first achieves rapid manufacturing through conventional laser cutting, then eliminates the harmful ridged profiles through subsequent smoothing operations, thereby resolving the contradiction between manufacturing speed and edge quality
Solution Approach 2:
The patent modifies laser operation parameters between preliminary and post-processing stages. The preliminary stage uses parameters optimized for cutting speed, while the post-processing stage uses different parameters (such as lower power, different pulse durations) optimized for smoothing. This parameter transformation allows the system to achieve both high productivity in the cutting phase and high precision in the finishing phase
2Ease of manufacture
If manual calibration of laser systems is performed, then device setup is possible, but the process is time-consuming and prone to errors leading to faulty products
Solution Approach 1:
The patent implements self-calibration capabilities where the laser system automatically adjusts its parameters using feedback from the manufacturing process and predictive data from machine learning models. This eliminates the need for time-consuming manual calibration by operators, allowing the system to self-optimize for each specific dental appliance manufacturing task, thereby reducing both calibration time and human error
Solution Approach 2:
The patent incorporates feedback mechanisms where the results of preliminary laser operations are analyzed, and this information is used to automatically adjust parameters for post-processing operations. The machine learning model uses historical data and real-time measurements to predict optimal laser parameters, creating a closed-loop system that continuously improves accuracy without manual intervention
3Reliability
If multiple laser passes are used to cut through the dental appliance, then cutting completeness is improved, but the ridged profile and stress concentrations are worsened
Solution Approach 1:
The patent converts the harmful effect of multiple laser passes creating ridged profiles into a beneficial process by using the same laser system to subsequently smooth those ridges. The preliminary passes that create stress concentrations are transformed into a substrate that is then refined by post-processing passes, turning the initial harm into a necessary intermediate state that leads to the final beneficial smooth finish
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 method produces dental appliances with smoother edges, reduced discomfort, and increased manufacturing efficiency, while automating calibration to enhance product accuracy and reduce errors and costs.
Implementation Method 1
causing one or more preliminary laser operations to form a laser line in the dental appliance
Implementation Method 2
laser operations to form a laser line in the dental appliance
Implementation Method 3
causing a one or more post-processing laser operations to smooth at least a portion of the laser line in the dental appliance
Implementation Method 4
post-processing laser operations to smooth at least a portion of the laser line
Data Source
AI summary
A method includes causing a sheet of plastic to be thermoformed over a mold to form a dental appliance and causing one or more preliminary laser operations to form a laser line in the dental appliance disposed on the mold. The dental appliance is associated with a dental arch of a user. The method further includes causing a one or more post-processing laser operations to smooth at least a portion of the laser line in the dental appliance disposed on the mold.