3D-Printed Dental Object Support Structure for Low-Distortion Sintering

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Solution Overview

Problem

Dental components produced by 3D printing are prone to damage during handling and processing, distortion during debinding and sintering, and have poor mechanical properties in the unsintered state, making them difficult to handle and process.

Innovation Solution

A method involving printing a substructure, an intermediate layer, and the dental object using specific materials, which includes an oxide ceramic for the dental object and a water-soluble support material, allows for improved handling and reduces distortion by distributing contact forces evenly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the dental object is printed without a substructure and intermediate layer, then the production process is simpler and faster, but the dental object is prone to mechanical damage during handling and processing in the unsintered state

Engineering Contradiction:

Improveproduction speedVSAvoidmechanical strength in unsintered state

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The support structure is segmented into two distinct parts: a substructure printed from production material that integrates with the final dental object, and an intermediate layer printed from removable support material. This segmentation allows the dental object to rest on a stable base during printing while enabling easy removal of the intermediate support layer without damaging the fragile dental object.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate layer acts as a mediator between the substructure and the dental object. It provides temporary support during printing and handling, then can be cleanly removed (e.g., by water dissolution) to leave the dental object resting stably on the substructure, preventing mechanical damage throughout the process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the dental object is printed with a substructure and intermediate layer, then mechanical damage during handling is reduced, but the production process becomes more complex and time-consuming

Engineering Contradiction:

Improvemechanical strength in unsintered stateVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The substructure is printed from the same production material as the dental object in the same printing process, merging the support structure creation with the main object fabrication. This eliminates the need for separate support structure printing and subsequent removal steps, simplifying the overall process while maintaining mechanical protection.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the dental object is sintered without a substructure, then the sintering process is simpler, but the dental object distorts due to unevenly distributed contact surface

Engineering Contradiction:

Improvesintering process complexityVSAvoiddimensional accuracy after sintering

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The support system is segmented into a permanent substructure that remains with the dental object through sintering and a temporary intermediate layer that is removed before sintering. The substructure provides a distributed contact surface that maintains dimensional accuracy during sintering, while the intermediate layer enables easy removal of overhanging or delicate portions.

Inventive Principle:

Principle #1Segmentation

4Reliability

If a thick intermediate layer is used, then the dental object is better protected during handling, but the fit between the dental object and substructure becomes poor

Engineering Contradiction:

Improvemechanical protection during handlingVSAvoidfit between dental object and substructure

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Instead of using a uniformly thick intermediate layer, the support is applied partially only where needed - the intermediate layer is printed only in areas requiring temporary support, while the dental object makes direct contact with the substructure in areas where precise fit is critical. This partial application maintains both protection and fit.

Inventive Principle:

Principle #16Partial or excessive action

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 reduced mechanical damage, improved handling, and minimized sintering distortion, facilitating easier polishing and automation of reworking processes.

Implementation Method 1

the support material comprises a water-soluble support material

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

allows for improved handling and reduces distortion by distributing contact forces evenly

Methodology Applied

Scientific EffectForce distribution:

Data Source

PatentUS20250375273A1Method of producing a dental object

Publication Date: 2025.12.11 IVOCLAR VIVADENT AG

AI summary

A method of producing a dental object, including 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 production material for the dental object on the intermediate layer.