Denture Mill Blanks for Congruent, Repair-Free CAD/CAM Production
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Solution Overview
Problem
Existing methods for producing dentures using standard dentures require significant manual adjustments and replication steps, leading to aesthetically unsatisfactory results with visible repair marks and difficulty in achieving high congruence, especially for patients with malocclusion.
Innovation Solution
A mill blank for dentures comprising a denture plate cutting part and connected cut members for front teeth and molar members, designed to facilitate efficient CAD/CAM production of aesthetically pleasing dentures by replicating a highly congruent denture, with artificial teeth cutting parts and fixing parts arranged to minimize cutting and exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments are made to achieve high congruence, then the denture fits the patient's oral cavity well, but visible repair marks appear and aesthetic appearance deteriorates
Solution Approach 1:
The mill blank is pre-designed with predetermined tooth arrangement patterns and pre-formed cervical parts that replicate the final adjusted denture shape. This preliminary preparation eliminates the need for subsequent manual adjustments and repairs, achieving both high congruence and aesthetic appearance without repair marks.
Solution Approach 2:
The mill blank copies the exact shape and tooth arrangement of the highly congruent adjusted denture. By creating a replica mill blank that includes the precise cervical part shapes and tooth positions achieved after manual adjustment, the replication process produces a final denture that matches the adjusted version without requiring additional repairs.
2Productivity
If standard denture replication is performed, then production time is reduced, but difficulty in achieving high congruence for malocclusion patients increases
Solution Approach 1:
The mill blank incorporates locally optimized features including predetermined tooth arrangement patterns specific to different patient conditions (including malocclusion), and pre-formed cervical parts with shapes adapted to individual patient anatomy. This localized customization within the standardized mill blank structure enables high congruence for malocclusion patients while maintaining efficient replication production.
3Adaptability or versatility
If multiple cutting and assembly steps are performed, then denture customization is improved, but device complexity and production difficulty increase
Solution Approach 1:
The mill blank merges multiple functions into a single integrated structure: the denture plate body, multiple artificial teeth with predetermined arrangements, and pre-formed cervical parts are all combined in one piece. This integration eliminates the need for separate cutting and assembly steps for each component, reducing production complexity while maintaining customization capabilities through the pre-designed tooth patterns.
4Manufacturing precision
If fixing parts are exposed during cutting, then assembly accuracy is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The cervical parts are designed as thin-film-like structures that cover and conceal the fixing parts during the cutting process. These cervical parts act as protective layers that hide the functional but aesthetically undesirable fixing components, allowing assembly accuracy features to be exposed during manufacturing while maintaining aesthetic appearance in the final product.
Data Source
AI summary
A mill blank for dentures; wherein artificial teeth cutting parts in cut members for front teeth each have a shape such that a thickness defined as a distance between a labial surface and a lingual surface of the artificial teeth cutting part is larger than a thickness of a corresponding standard front tooth, and a width defined as a distance between a mesial surface and a distal surface of the artificial teeth cutting part is substantially equal to a width of the standard tooth, and wherein fixing parts in the cut members for front teeth are each connected to the cut member for front teeth so as not to be exposed to a surface when the artificial teeth cutting part in the cut member for front teeth and a denture plate cutting part are cut.