3D Printed Dental Objects With Support Substructure for Sintering Stability
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Solution Overview
Problem
Dental objects produced by 3D printing are prone to damage during handling and processing due to uneven contact areas, warping, and poor mechanical properties in the unsintered state, making them difficult to machine and polish effectively.
Innovation Solution
A method involving the printing of a substructure, an intermediate layer of support material, and the dental object itself, using an oxide ceramic material and water-soluble support material, with a substructure providing a stable base for the dental object, allowing for improved handling and reduced sintering distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dental objects are printed directly without substructure, then printing process is simpler, but mechanical strength and handling stability deteriorate
Solution Approach 1:
A substructure printed from support material serves as an intermediary carrier that provides mechanical strength and stability during handling. The substructure acts as a temporary scaffold that supports the fragile dental object through subsequent processing steps, enabling easy manufacture of thin-walled structures while maintaining handling stability.
2Manufacturing precision
If dental objects are polished in unsintered state, then surface roughness is reduced, but mechanical damage and cracks increase
Solution Approach 1:
The substructure provides beforehand cushioning and support to the dental object during polishing operations. By embedding the object in a supportive matrix, the substructure prevents mechanical damage and crack formation that would otherwise occur when polishing fragile unsintered dental objects, thus protecting structural integrity while enabling surface refinement.
3Stability of the object's composition
If contact area during sintering is increased, then warping is reduced, but device complexity increases
Solution Approach 1:
The substructure and dental object are merged into a single integrated printed structure. The substructure is printed simultaneously with the dental object in the same printing process, combining support functionality with the object fabrication. This merging approach increases contact area during sintering to reduce warping, while avoiding additional device complexity by using the same printing system.
4Length of moving object
If thinner dental objects are produced, then aesthetic and functional performance is improved, but mechanical strength and handling ease deteriorate
Solution Approach 1:
The system is segmented into two functional parts: the thin dental object (crowns, bridges, veneers) and the thicker substructure. The dental object maintains its thin dimensions for aesthetic and functional performance, while the substructure provides the necessary mechanical strength and handling ease. This segmentation allows thin-walled structures to be produced without sacrificing structural integrity.
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 the production of thinner dental objects with enhanced mechanical properties, reduced handling damage, and efficient polishing, while minimizing sintering distortion and deformation.
Implementation Method 1
the support material is melted after printing
Implementation Method 2
the dental object is sintered together with the substructure
Data Source
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AI summary
Method for manufacturing a dental object, comprising the steps of printing (S101) a substructure; printing (S102) an intermediate layer from a support material on the substructure; and printing (S103) the dental object from the manufacturing material for the dental object on the intermediate layer.