Denture Base Coupling via Recesses and Protrusions
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Solution Overview
Problem
In digital denture design and manufacturing, existing methods face challenges in creating improved copy dentures that maintain a secure fit and aesthetics, particularly due to bone retraction leading to reduced fit between the gingiva and the denture, and the need for precise modification and coupling of denture base and teeth models.
Innovation Solution
A computer-implemented method involving obtaining a digital model of an existing denture, segmenting it into a base and teeth models, modifying the anatomy, designing a coupling arrangement with recesses and protrusions, and generating digital data files for 3D manufacturing, ensuring secure assembly and improved aesthetics by preventing undercuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the denture base anatomy is modified to improve aesthetics, then the aesthetic appearance is improved, but the coupling security between teeth and base may be compromised due to potential undercuts
Solution Approach 1:
The patent applies preliminary action by modifying the denture base anatomy to accommodate the teeth models before final assembly. The base is prepared with recesses and the teeth are prepared with protrusions in advance, ensuring that the coupling arrangement is designed before any potential undercut issues arise during assembly.
Solution Approach 2:
The patent segments the denture into separate components - the denture base model and the teeth models - allowing independent modification of each component's anatomy. This segmentation enables the base to be modified for aesthetics while the teeth are separately prepared with protrusions to ensure secure coupling, resolving the contradiction between aesthetic improvement and coupling security.
2Manufacturing precision
If digital design and manufacturing processes are used to improve manufacturing precision, then the precision of denture fabrication is improved, but the complexity of the design and manufacturing process increases
Solution Approach 1:
The patent uses digital copying by creating digital models of the denture base and teeth that can be precisely replicated through 3D printing or other digital manufacturing processes. The digital models serve as accurate copies that maintain precise dimensions and anatomical features, achieving high manufacturing precision while the software automates the complex design steps to reduce process complexity.
Solution Approach 2:
The patent replaces traditional mechanical denture fabrication processes with digital design and manufacturing systems. Computer-aided design (CAD) software and 3D printing technology substitute for manual modeling and casting processes, improving precision while the automated digital workflows manage the complexity of the manufacturing process.
3Adaptability or versatility
If the denture is designed as separate base and teeth components to improve manufacturing flexibility, then the manufacturing flexibility is improved, but the assembly complexity increases due to the need for precise coupling arrangements
Solution Approach 1:
The patent segments the denture into separate base and teeth components that can be manufactured independently using different materials, processes, or by different technicians. This segmentation provides manufacturing flexibility while the standardized coupling arrangement protocol (recesses and protrusions) simplifies the assembly process, preventing it from becoming overly complex.
Solution Approach 2:
The patent applies local quality by creating specific recesses in the base and protrusions on the teeth at the coupling interfaces, while the rest of the components can be manufactured with different qualities or by different methods. This localized specialization at the coupling points ensures precise assembly while maintaining overall manufacturing flexibility for the rest of the denture components.
Data Source
AI summary
Computer implemented methods and user interfaces for facilitating the design of a so-called copy denture, whereby an existing denture is reproduced after making changes to the existing denture to improve fit, aesthetics or other parameters. A method may include the steps of obtaining a digital model of an existing denture, segmenting the digital model of the existing denture into an intermediate denture base model and at least one intermediate denture teeth model, and generating a digital data file of a final denture base model based on the intermediate denture base model and providing a digital data file of at least one final denture teeth model based on the at least one intermediate denture teeth model.