Digital Denture Design with Segmented Coupling
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Solution Overview
Problem
Current digital denture design and manufacturing methods for copy dentures do not adequately address the need for improved aesthetics and secure coupling while preventing undercuts, especially in cases of bone retraction where the fit between the gingiva and denture is compromised.
Innovation Solution
A computer-implemented method that involves 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 to ensure secure assembly, and generating digital data files for the final denture models, which can be manufactured using 3D printing or milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the anatomy of the denture base model is modified to improve aesthetics, then the aesthetic appearance is improved, but the risk of creating undercuts increases
Solution Approach 1:
The patent applies preliminary action by designing the coupling arrangement (recesses and protrusions) before finalizing the anatomy modification. The coupling arrangement is created in the intermediate denture base model before the anatomy is modified, ensuring that the structural integrity and coupling security are established beforehand. This prevents undercuts from forming during subsequent anatomy modifications while still allowing aesthetic improvements to be made.
2Ease of manufacture
If the denture is segmented into base and teeth models for independent modification, then the ease of design and aesthetics is improved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the denture digital model into separate components: an intermediate denture base model and at least one intermediate denture teeth model. This segmentation allows each component to be modified independently, providing design flexibility and ease of manufacture. The base model can be optimized for anatomy and aesthetics while the teeth model can be optimized for coupling, and both can be manufactured separately and assembled.
Solution Approach 2:
The patent applies the nesting principle by creating a coupling arrangement where the intermediate denture teeth model fits into the intermediate denture base model through recesses and protrusions. The teeth model is essentially nested within the base model structure, allowing for secure integration while maintaining separate manufacturability. This nested configuration provides both design flexibility from segmentation and structural integrity from the nested coupling.
3Stability of the object's composition
If a coupling arrangement with recesses and protrusions is designed, then the mechanical stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The coupling arrangement is segmented into discrete recesses in the base model and corresponding protrusions on the teeth model. This segmentation allows for standardized, modular coupling elements that can be manufactured using conventional 3D printing or milling processes. The simplicity of the recess-protrusion geometry reduces manufacturing complexity while achieving stable mechanical integration.
Data Source
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AI summary
Disclosed are 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.