Dental Mold Fabrication Data Workflow for High-Volume Custom Aligners
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Solution Overview
Problem
Existing dental mold manufacturing systems face inefficiencies, including manual processing, lack of uniqueness in molds, issues with holes and structural stability, excessive resin use, inefficient packing, and suboptimal laser marking, which hinder high-volume, automated production of customized dental aligners.
Innovation Solution
A system and method for automated fabrication that processes 3D jaw and teeth data to generate molds, cutting paths, and laser marking data, optimizing resin use, reducing manual intervention, and improving tray packing efficiency through a centralized manufacturing terminal and distributed fabrication terminals, utilizing data packages and verification processes to ensure accuracy and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processing methods are used for dental mold manufacturing, then flexibility and customization are maintained, but productivity and manufacturing efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical processing with automated computer-controlled systems. A computer reads 3D jaw and teeth data, automatically generates mold data, and controls fabrication terminals to produce molds without manual intervention, thereby dramatically improving productivity while maintaining customization through digital data processing.
2Manufacturing precision
If traditional mold making methods are used, then structural stability is maintained, but manufacturing precision and mold quality deteriorate
Solution Approach 1:
The patent uses digital 3D data of jaw and teeth as a precise master copy, from which accurate mold data is generated through computer processing. This digital copying and processing ensures high manufacturing precision and consistent mold quality without compromising structural stability, as the digital model can be perfectly replicated and refined.
3Reliability
If excessive resin is used in mold fabrication, then complete coverage and structural integrity are achieved, but loss of substance and material waste increase
Solution Approach 1:
The patent optimizes resin usage by precisely controlling fabrication parameters through computer-controlled systems. The automated generation of mold data allows for optimized material deposition patterns, ensuring complete coverage and structural integrity while minimizing resin consumption through precise parameter control during the fabrication process.
4Productivity
If simple packing methods are used for trays, then ease of operation is maintained, but productivity and space utilization deteriorate
Solution Approach 1:
The patent improves tray packing efficiency by optimizing spatial parameters through computer-controlled systems. The automated system calculates optimal mold arrangements on trays, maximizing space utilization and productivity while maintaining ease of operation through systematic, algorithm-driven packing methods that simplify the complexity of manual optimization.
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 mold quality, reduced errors, and optimized resin usage, while minimizing manual cutting and laser marking, ensuring efficient and precise manufacturing.
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 volume manufacturing of a plurality of unique items are provided. In some embodiments, a method includes: (a) initiating a predefined fabrication processing time period, (b) retrieving a fabrication data package containing manufacturing data, (c) verifying the fabrication data package for accuracy and completeness of the manufacturing data contained therein, and (d) performing at least one fabrication process in accordance with the manufacturing data contained in the fabrication data package. If the predefined fabrication time period has not expired, the method can include repeating (b) through (d). If the predefined fabrication time period has expired, the method can include generating a status report.