Dental Appliance Laser Trimming for Variable Thickness Cutting
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Solution Overview
Problem
Laser cutting systems face challenges such as material discoloration, brittleness, and thickness variations, which can lead to undesirable changes in material characteristics and mixing with support materials, especially when cutting at high speeds or with high energy beams.
Innovation Solution
A system and method that adjusts the laser energy, optical components, and fixture movement to maintain a predetermined ratio of laser energy to part material thickness, ensuring precise cutting without damaging the support material, using a control mechanism to adjust laser power, optical components, and fixture speed based on thickness data.
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 characteristics change (becoming more brittle) and discoloration occurs
Solution Approach 1:
The system dynamically adjusts laser power and beam parameters in real-time based on material thickness feedback, allowing high cutting speeds while preventing excessive heat accumulation that causes brittleness and discoloration
Solution Approach 2:
The patent changes laser parameters (power, pulse duration, frequency) based on material thickness to optimize cutting speed while minimizing harmful thermal effects on material characteristics
2Manufacturing precision
If laser cutting is used to cut through thick material, then cutting capability is improved, but the laser may not cut all the way through or vaporization effectiveness is reduced
Solution Approach 1:
The system dynamically adjusts laser power and focuses the beam based on real-time thickness measurements, ensuring complete penetration through thick material while maintaining efficient vaporization
Solution Approach 2:
The system performs preliminary thickness measurement and calibration before cutting, allowing optimization of laser parameters in advance to ensure complete cutting through thick material
3Manufacturing precision
If laser cutting is used on thin material, then cutting precision is improved, but the laser may cut through into support material causing mixing and discoloration
Solution Approach 1:
The system dynamically reduces laser power and adjusts beam parameters when cutting thin material, preventing penetration through the material and into the support structure
Solution Approach 2:
The patent changes laser parameters based on material thickness to match the energy input to the material being cut, preventing damage to underlying support materials
4Ease of manufacture
If fixed laser parameters are used for calibration, then setup simplicity is improved, but effectiveness is reduced when material thickness varies
Solution Approach 1:
The system transitions from fixed to dynamic parameters, automatically adjusting laser power and beam characteristics based on real-time thickness measurements
Solution Approach 2:
The system uses thickness measurement feedback to continuously adjust laser parameters, maintaining optimal cutting effectiveness across varying material thicknesses
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 precise cutting of materials without substantial changes in edge characteristics or mixing with support materials, allowing for efficient cutting through varying thicknesses and reducing brittleness and discoloration, while maintaining support integrity.
Implementation Method 1
a laser generating component for producing a laser beam
Implementation Method 2
the material may not be vaporized as effectively
Data Source
AI summary
Laser cutting systems and methods. In some examples, a cut path along a gum line of a dental appliance for trimming excess material from the dental appliance may be identified. The excess material may be trimmed from the dental appliance by cutting along the cut path using a laser. Cutting along the cut path may include adjusting an energy of a laser beam of the laser during the cutting to reduce a brittleness at an edge of the gum line. Adjusting the energy of the laser beam may include adjusting one or more of: a power of the laser and a focal length of an optical system of the laser. An orientation of the dental appliance may be adjusted relative to the laser beam during the cutting.