Dental Prosthesis Overlay with Inverted T-Profile
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Solution Overview
Problem
Traditional dental prostheses are prone to fractures due to occlusal forces, requiring frequent replacements and are time-consuming and costly to manufacture, as they lack digital records of individual teeth components.
Innovation Solution
A two-part dental prosthesis system featuring an implant frame with an inverted T-profile and a complementary overlay, allowing for a secure and durable fit using CAD/CAM technology, enabling digital recording and easier reproduction of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional acrylic processed dental hybrid restorations are used with manually attached denture teeth, then the prosthesis can be manufactured with conventional methods, but the prosthesis is prone to fracture and requires significant time and skill in the laboratory
Solution Approach 1:
The prosthesis is divided into two separate components: a framework and an overlay. The overlay is fabricated separately and then bonded to the framework, allowing each component to be optimized independently. This segmentation enables the overlay to bear the occlusal loads while the framework provides structural support, significantly improving fracture resistance and durability compared to traditional monolithic acrylic constructions.
Solution Approach 2:
The prosthesis combines two different materials: the framework (typically metal or ceramic) and the overlay (acrylic or composite material). This composite construction leverages the strength and rigidity of the framework while utilizing the aesthetic properties and comfort of the overlay material, creating a prosthesis that is both durable and aesthetically pleasing with superior mechanical properties.
2Ease of manufacture
If traditional manual methods are used to manufacture dental prostheses, then flexibility in customization is possible, but the process requires high skill level and significant time in the laboratory
Solution Approach 1:
The framework is fabricated first as a preliminary structure that serves as a foundation for the overlay. By preparing the framework in advance with precise positioning features and bonding surfaces, the subsequent overlay fabrication and assembly process is greatly simplified and accelerated, reducing overall manufacturing time and skill requirements while maintaining customization capabilities.
Solution Approach 2:
The overlay is created as a separate copy or addition to the framework structure. This allows the overlay to be fabricated using standardized techniques and materials that can be readily applied to various framework designs, simplifying the manufacturing process while still enabling patient-specific customization through digital imaging and planning software.
3Ease of manufacture
If traditional acrylic bonding is used to attach denture teeth to the framework, then the prosthesis can be assembled, but the acrylic bond is weak and teeth may break under occlusal forces
Solution Approach 1:
By separating the prosthesis into framework and overlay components that are bonded together, the bonding interface is created between two precisely prepared surfaces rather than attempting to bond individual teeth to a framework. This segmented approach allows for larger bonding surface areas and more controlled bonding conditions, significantly improving bond strength and reducing the risk of tooth detachment under occlusal loads.
Solution Approach 2:
The bonding process utilizes optimized parameters including surface preparation techniques (etching, roughening), controlled bonding agent application, and precise curing conditions. These parameter changes transform the weak traditional acrylic bond into a strong, durable connection that can withstand occlusal forces, while the segmented design allows this bonding to occur between larger surfaces rather than at multiple small tooth interfaces.
Data Source
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AI summary
A dental prosthesis (10), comprising an implant frame (12) having a first engagement profile; and an overlay (30) to provide, or afford mounting of, the two or more teeth, and having an internal cavity that extends along a substantial length of the overlay and defining a complementary second engagement profile. A method: generating a first digital data file representing the form of the frame defined by the positions of implant locations and by a projecting overlay- engaging profile, generating a second digital data file being representing a form for the multiple teeth, defined in part by an occlusal table; generating a third digital data file being a tissue digital data file, defined in part by said form for the multiple teeth and in part by a frame-engaging cavity profile; modifying said first and/or said third digital data files such that the third digital data file defines a prescribed minimum thickness.