Denture Milling with Deformable Wax Adjustments
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Solution Overview
Problem
Current dental prosthesis manufacturing methods are labor-intensive, prone to errors, and fail to produce durable, aesthetically pleasing, and cost-effective dentures with minimal trial fittings, particularly for removable dentures like complete and partial dentures.
Innovation Solution
A method involving a preliminary try-in denture made from synthetic materials with distinct color zones, where the artificial teeth and denture base are milled from different colored zones, allowing for adjustments and refinement through a deformable wax, followed by a final mold creation and polymerization to produce a durable and aesthetically pleasing denture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional labor-intensive methods are used to manufacture dentures, then manual adjustments and fittings can be made, but the process requires multiple trial fittings, is time-consuming, and labor-intensive
Solution Approach 1:
The patent applies preliminary action by creating a precise digital 3D model of the patient's oral cavity and pre-positioning denture teeth in the virtual model before manufacturing. This preliminary digital planning allows the denture to be manufactured with correct positioning from the start, eliminating the need for multiple trial fittings and reducing adjustment time while maintaining ease of operation.
2Manufacturing precision
If CAD/CAM systems are used for fixed restorative dentistry, then processing errors are reduced, but the systems are designed for cemented prosthetics and not optimized for removable dentures
Solution Approach 1:
The patent applies universality by developing a CAD/CAM system that can handle both fixed restorative dentistry and removable denture fabrication. The system uses a universal digital workflow that captures oral cavity geometry, allows virtual positioning of denture teeth, and generates manufacturing data for removable prosthetics, making the same technology applicable to multiple dental applications.
3Ease of manufacture
If traditional denture fabrication methods are used, then multiple steps can be performed by skilled artisans, but each step introduces potential processing errors that affect fit and occlusion
Solution Approach 1:
The patent applies mechanics substitution by replacing manual mechanical processes (wax modeling, hand carving, trial fittings) with computer-controlled digital processes. The CAD/CAM system performs precise digital measurements, virtual tooth positioning, and controlled manufacturing, eliminating human error in each step while maintaining the flexibility to adjust parameters digitally before final production.
4Adaptability or versatility
If manual wax modeling is used for denture fabrication, then aesthetic options are unlimited, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent applies local quality by allowing digital customization of specific regions of the denture while maintaining overall precision. The software enables independent adjustment of tooth position, shape, and aesthetics in different areas of the arch, and selective modification of denture base contours, providing aesthetic versatility without requiring complete manual remodeling of the entire prosthesis.
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 results in a better-fitting, longer-lasting denture with reduced labor costs and time, achieving precise fit and aesthetics while minimizing trial fittings, and can be completed in a dental office with minimal equipment.
Implementation Method 1
The wax is a deformable material that is subject to deformation when a threshold stress is applied thereto.
Implementation Method 2
removing denture base material from the block to form the buccal, labial, and flange region of the denture base; removing denture base material from the block to form a first portion of the gingival regions
Implementation Method 3
The denture base material is cured to form a completed denture
Data Source
AI summary
A method of fabricating a denture, comprising milling a preliminary try-in denture from denture material comprising a layer of denture base material contiguous with a layer of denture tooth material. Denture base material is removed from the block to form a first part of the, labial, buccal, gingival, and flange regions of the denture base to form a preliminary denture. A preliminary mold is created from this preliminary denture. The preliminary denture is then further modified with deformable waxes in gingival and anterior tooth recesses to form a preliminary try-in denture, which is fitted to a patient and adjusted to optimal dimensions. The adjusted try-in denture is then reproduced by further molding methods, producing the final denture.