Dental Shell Mold Segmentation for Undercut Feature Removal
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Solution Overview
Problem
The challenge with existing molds is the difficulty in removing shells without damaging or deforming them due to features with significant undercuts or complex shapes, limiting the types of features that can be included in the mold.
Innovation Solution
Molds with separable features are designed, featuring weakened regions that allow the separable features to be detached from the main body, enabling the incorporation of complex and retentive features, and the mold can be segmented into sections for easier removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If molds include features with significant undercuts or complex shapes, then the shell can achieve enhanced functional features, but the shell becomes difficult to remove without damage or deformation
Solution Approach 1:
The mold is divided into multiple separable features that can be detached from the main body. Each separable feature is connected via weakened regions that allow controlled breaking, enabling the shell to be removed in sections rather than as a single complex piece, thus resolving the contradiction between feature complexity and removal ease
2Reliability
If the mold includes retentive features for shell retention, then the shell can be securely held during forming, but the shell becomes difficult to remove without damage
Solution Approach 1:
The mold is designed with pre-determined weakened regions in the separable features before the forming process. These weakened regions are intentionally created to break at specific points during shell removal, allowing the mold to provide strong retention during forming while enabling easy removal afterward without damaging the shell
3Ease of manufacture
If the mold is designed as a single integrated piece, then manufacturing the mold is simpler, but removing shells with complex features becomes difficult
Solution Approach 1:
The mold is segmented into a main body and multiple separable features that can be manufactured separately and then assembled. This approach maintains relative manufacturing simplicity for each component while enabling the creation of complex overall features through the combination of separate elements, resolving the contradiction between manufacturing ease and feature complexity
Data Source
AI summary
A method is for manufacturing a shell. The method includes forming the shell over a mold. The mold includes a first portion and a second portion. One or more weakened regions of the mold are associated with the first portion and the second portion. The method further includes causing the first portion of the mold to separate from the second portion of the mold via the one or more weakened regions. The method further includes removing the first portion of the mold from the shell. The method further includes removing the second portion of the mold from the shell. The shell is configured to be worn in a mouth of a patient.