Automated Dental Mold Trimming via Digital Cutting Loop
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Solution Overview
Problem
Conventional methods for fabricating dental aligners are time-consuming and require multiple steps, often delaying treatment and preventing real-time, instant treatment for patients.
Innovation Solution
The system uses a digital model of teeth to determine a cutting loop path and apply a drape wall, allowing for automated cutting and trimming of dental molds and oral appliances using a single machine, enabling efficient fabrication of aligners directly at dental offices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to fabricate dental aligners at a central lab, then manufacturing precision can be maintained, but treatment time is delayed and real-time treatment is not possible
Solution Approach 1:
The patent replaces manual mechanical fabrication processes with automated CNC machining systems. The CNC machine automatically mills the dental mold and aligner based on digital models, eliminating the need for manual mold-making processes at a central lab. This automation enables the dental office to fabricate aligners on-demand, reducing treatment delay while maintaining precision through computer-controlled machining.
Solution Approach 2:
The dental office becomes self-sufficient in aligner fabrication by having its own CNC machine and digital modeling capability. Instead of sending cases to an external central lab, the dentist can design and fabricate aligners in-house, enabling real-time treatment adjustments and eliminating outsourcing delays.
2Manufacturing precision
If multiple steps are used in fabricating molds and aligners, then manufacturing precision can be maintained, but the process becomes time-consuming and complex
Solution Approach 1:
The patent combines multiple fabrication steps into a single integrated CNC machining process. The CNC machine performs both mold fabrication and aligner fabrication in one automated sequence, eliminating the need for separate manual steps. The digital model is directly milled into the mold material, and the aligner is then fabricated from that mold in the same machine, streamlining the entire workflow.
Solution Approach 2:
The system performs preliminary digital modeling and path planning before physical fabrication begins. The cutting loop path is calculated and the drape wall is applied to the digital model beforehand, allowing the CNC machine to execute a pre-planned automated fabrication sequence without manual intervention during the actual machining process.
3Manufacturing precision
If complex cutting paths are used to trim dental molds, then manufacturing precision can be maintained, but the cutting process becomes difficult and time-consuming
Solution Approach 1:
The patent replaces complex manual cutting operations with automated CNC machining. The CNC system automatically executes the calculated cutting loop path, transforming the complex trimming task into a computer-controlled automated process. This eliminates the difficulty of manual complex cutting while maintaining precision through digital path control.
Solution Approach 2:
The cutting loop path is pre-calculated on the digital model before fabrication begins. By performing the path planning in the digital domain beforehand, the system simplifies the actual physical cutting operation, as the CNC machine simply needs to follow the pre-determined automated path rather than requiring complex manual guidance.
Data Source
AI summary
Systems and methods are disclosed for cutting and trimming dental molds and oral appliances by receiving a digital model of teeth, determining a cutting loop path and applying a drape wall to the cutting loop to generate a simplified tooth base in a dental mold having an inner arch curve and an outer arch curve. The oral appliance may be formed on the dental mold and a cutter may be applied using a sweeping motion across the inner and outer arch curves.