Denture Reference Posts for Precise Bar Registration
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Solution Overview
Problem
The challenge in denture manufacturing using CAD/CAM technology is the precise and secure fitting of a complex-shaped bar into a denture, as traditional methods rely on plaster models that introduce delays and inaccuracies, and the bar's alignment is difficult to maintain without them.
Innovation Solution
An improved denture bar reference and registration system featuring a support bar with implant interfaces and reference posts inserted into an oversize cutout in the denture base, where the cutout is configured to interface with the reference posts, ensuring easy positioning and secure alignment of the bar relative to the denture base and patient's edentulous ridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CAD/CAM technology is used to manufacture dentures directly without plaster models, then manufacturing time is reduced and productivity is improved, but the precision of bar positioning and alignment deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-creating digital bar reference data and virtual registration features in the CAD model before denture manufacturing. The bar's position, orientation, and registration features are defined in advance within the digital design, allowing the denture to be manufactured with precise bar positioning capabilities without requiring traditional plaster models during production.
Solution Approach 2:
The patent uses copying by creating a digital replica or representation of the bar and its reference features within the CAD/CAM system. The virtual model of the bar with its registration features serves as a digital copy that guides the actual bar placement and alignment during denture fabrication, eliminating the need for physical plaster model copies.
2Manufacturing precision
If the full shape of the bar is used for reference and registration, then alignment accuracy should improve, but the complexity of fitting and securing the bar in the denture increases
Solution Approach 1:
The patent applies segmentation by dividing the bar reference system into distinct functional components: registration features (such as pins, slots, or geometric markers) that provide positioning information, and the main bar structure that provides support. This segmentation allows the complex bar shape to be managed through separate reference elements rather than requiring the entire bar geometry to be used for alignment.
Solution Approach 2:
The patent extracts only the essential registration features from the full bar shape for positioning purposes. Instead of using the complete complex geometry of the bar for reference and alignment, the system identifies and uses specific extracted features (such as reference pins, alignment slots, or digital markers) that provide sufficient positioning information while simplifying the fitting process.
3Manufacturing precision
If plaster models with implant analogs are used to align and position the bar, then positioning precision is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent replaces the mechanical plaster model system with a digital CAD/CAM system. Instead of using physical plaster models with implant analogs for bar alignment, the system uses computer-aided design and manufacturing with digital models that incorporate bar reference data, eliminating the need for physical model-making steps while maintaining positioning precision.
Solution Approach 2:
The patent uses digital copying to create virtual models of the patient's anatomy and implant positions directly from digital impressions or scans. These digital copies replace the traditional plaster model copies, allowing for precise bar positioning through software-based registration and planning without the time-consuming physical model-making process.
Data Source
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AI summary
An improved denture system is disclosed. An improved denture system has a support bar and an artificial denture base. The denture base has an oversize cutout and a corresponding cavity and the support bar has a plurality of reference posts which mechanically interface with the corresponding cavity so that the support bar is connected to the artificial denture base and provides reinforcement and stability to the denture system. The shape and position of the reference posts fully constrains the support bar in a fixed position with reference to the denture base. In one embodiment, the denture base snap-fits onto the support bar.