Dental Veneer Rapid Prototyping Support Structure
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Solution Overview
Problem
Current methods for producing dental articles, such as crowns and bridges, are inefficient and labor-intensive, particularly in achieving precise fit and aesthetic appearance, and often result in sinter deformation during the heating process without a support structure.
Innovation Solution
A process involving a rapid-prototyping technique to produce two parts, Part A (dental coping) and Part B (dental veneer), where Part A serves as a support structure during a heating step for Part B, allowing for efficient manufacturing and minimizing sinter deformation, with Part B being removable and potentially fused together using a fusing composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rapid-prototyping technique is used to produce a dental veneer (Part B), then productivity and ease of manufacture are improved, but sinter deformation occurs during the heating step without a support structure
Solution Approach 1:
A support structure (Part A) is introduced as an intermediary element during the heating step. This support structure prevents sinter deformation of the dental veneer (Part B) by providing mechanical stability while allowing the veneer to be produced using rapid-prototyping techniques. The support structure acts as a temporary mediator that ensures dimensional accuracy during the critical heating phase.
Solution Approach 2:
The support structure (Part A) is prepared in advance before the heating step, with its outer surface pre-formed to match the inner surface of the veneer. This preliminary preparation ensures that when the veneer is placed on the support structure, proper alignment and dimensional stability are achieved during the subsequent heating process, preventing deformation.
2Shape
If manual layering of ceramic slurries is used for veneering, then aesthetic appearance is improved, but loss of time and productivity are worsened
Solution Approach 1:
The manual mechanical process of layering ceramic slurries is replaced with a rapid-prototyping system that uses computer-controlled deposition of ceramic material. This substitution maintains the ability to create complex aesthetic shapes while dramatically reducing the time required, as the automated system can deposit material layer by layer without manual intervention.
Solution Approach 2:
The manufacturing process transitions from manual slurry application to a controlled deposition process where parameters such as deposition rate, layer thickness, and curing conditions are optimized. This allows the production of high-quality aesthetic veneers in a fraction of the time required for manual layering, while maintaining or improving dimensional precision.
3Productivity
If pressing technique with a mould is used for veneering, then productivity is improved, but manufacturing precision and fit are worsened
Solution Approach 1:
The inner surface of the veneer (Part B) is pre-formed during the rapid-prototyping process to precisely match the outer surface of the support structure (Part A). This preliminary precision shaping ensures that when the veneer is removed from the support structure, an accurate fit is achieved without requiring post-processing adjustments, maintaining both productivity and precision.
Solution Approach 2:
The traditional pressing technique using physical moulds is replaced with a rapid-prototyping deposition process. This substitution allows for direct digital-to-physical manufacturing where the veneer is built layer by layer with high precision, eliminating the need for physical moulds while achieving better fit accuracy through computer-controlled dimensional control.
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 method enables quick, cost-effective, and precise production of dental articles in various shapes and sizes, reducing material usage and simplifying the manufacturing process, while maintaining the strength and aesthetic requirements of dental restorations.
Implementation Method 1
produced with the aid of a rapid-prototyping technique
Implementation Method 2
a first heating step, wherein Part A is serving as support structure for Part B during said heating step
Data Source
Figure 1
Figure 2~3
AI summary
In one aspect the invention relates to a process for producing a dental article comprising at least two parts, Part A (e.g. coping) and Part B (e.g. veneer), Part A and Part B each having a 3-dim. structure and an outer and an inner surface, the outer surface of Part A having a shape which essentially corresponds to the shape of the inner surface of Part B, Part B comprising a material with a porous section and being produced with the aid of a rapid-prototyping technique, the process comprising a first heating step, wherein Part A is serving as support structure for Part B during said heating step.