Automated Dental Prosthesis Fabrication via Digital Design
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Solution Overview
Problem
Current methods for producing dental prostheses, especially aesthetically demanding ones with color layers or transparency gradations, lack efficiency and accuracy in automated production processes.
Innovation Solution
The method involves providing 3D data of the oral situation, digitally constructing the prosthesis base and teeth, and using automated processes like stereolithography, inkjet printing, or CAD/CAM milling for the interior, followed by an outer layer application using Fused Deposition Modeling, with specific materials for each process to achieve multicolored or transparent gradations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional powder/liquid technology methods are used for denture fabrication, then the process is well-established and controllable, but the production time is long and automation is limited
Solution Approach 1:
The patent replaces conventional mechanical mixing and layering processes with automated digital fabrication systems. Digital impressions and CAD designs are directly transferred to automated milling or additive manufacturing equipment, eliminating manual mechanical operations and significantly reducing fabrication time while increasing automation.
Solution Approach 2:
The patent changes the fundamental parameters of the fabrication process by transitioning from material-based conventional methods (powder/liquid mixing, manual layering) to digital-based methods (CAD/CAM data, automated toolpaths). This parameter change enables automation and reduces time by eliminating intermediate manual steps.
2Manufacturing precision
If manual layering techniques are used for aesthetic dental work, then control over material and shade variation is achieved, but the process is time-consuming and difficult to automate
Solution Approach 1:
The patent segments the denture fabrication into distinct digital stages: digital impression capture, virtual tooth setup with color specification, and automated fabrication. This segmentation allows aesthetic parameters to be precisely defined in the digital domain before manufacturing, maintaining color control while enabling parallel automated processing that improves productivity.
Solution Approach 2:
The patent uses digital copies and virtual models to represent the final aesthetic outcome before physical fabrication. The CAD model contains all aesthetic information (tooth shape, color, positioning) that is then precisely reproduced by automated milling or additive manufacturing, eliminating the need for time-consuming manual layering while maintaining aesthetic precision.
3Ease of manufacture
If separate fabrication of dental arch and gingival imitation is performed, then component control is improved, but the number of steps and bonding requirements increase complexity
Solution Approach 1:
The patent merges the fabrication of the dental arch and gingival imitation into a single integrated automated process. Both components are fabricated together in one setup using the same digital model and automated equipment, eliminating the need for separate fabrication steps and subsequent bonding operations, thus reducing process complexity while maintaining component control.
Solution Approach 2:
The patent employs a universal automated fabrication system that can produce both the dental arch and gingival imitation components in a single process. This multi-functional approach eliminates the need for separate specialized processes and bonding steps, reducing overall process complexity while maintaining the advantages of controlled component fabrication.
4Productivity
If rapid prototyping methods are used for denture production, then production speed is improved, but material limitations and aesthetic quality are compromised
Solution Approach 1:
The patent employs composite material strategies where the denture base and teeth are fabricated from materials specifically selected for both their manufacturability with automated processes and their aesthetic properties. The system uses digital material selection to match aesthetic requirements with automated fabrication capabilities, ensuring high-quality results without compromising production speed.
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
This approach enhances the production of aesthetically pleasing dental prostheses by improving accuracy, reproducibility, and reducing fabrication time, while ensuring material safety and cost-effectiveness.
Implementation Method 1
The dental arch or the gingival imitation is constructed layer by layer using known rapid prototyping methods, in particular using stereolithography and photopolymerizable layers
Implementation Method 2
at least a second material is applied as an outer layer using an automated process, by means of Fused Deposition Modelling (FDM)
Implementation Method 3
at least a second material is applied as an outer layer using an automated process, by means of Fused Deposition Modelling (FDM)
Implementation Method 4
CAD/CAM milling with a material 1B
Implementation Method 5
inkjet printing with a material 2B
Data Source
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AI summary
The method involves provisioning 3D data of mouth situation in edentulate state and performing digital designing of a denture base for a lower and an upper jaw. Virtual teeth are digital positioned with appropriate occlusion based on tooth shape selected according to aesthetic criteria. A dental arch and the denture base are produced using automated process from groups of layer-buildings and material-removing process. The dental arch and dental base are produced using any one of processes such as Stereolithography (SLA), inkjet printing, fused deposition modeling (FDM) and CAD/CAM cutting.