Denture Superstructure Modeling via 3D Scanning and CAD/CAM

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Solution Overview

Problem

Current denture manufacturing processes are cumbersome, time-consuming, and often result in user-unfriendly, non-customizable dentures with issues like sore spots, poor retention, and bacterial growth, taking two to six weeks to complete and requiring manual shaping and attachment.

Innovation Solution

A method involving 3D scanning to obtain representations of the denture and dental arch with implants, combining these to virtually model a superstructure for precise CAD/CAM manufacturing, allowing for automatic generation of the superstructure and customization of the denture's fit and design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual shaping and manufacturing processes are used for dentures, then customization and fit adjustment are possible, but the process becomes time-consuming (2-6 weeks) and cumbersome

Engineering Contradiction:

ImprovecustomizationVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical shaping processes with automated CAD/CAM systems. Digital impressions and 3D scanning data are processed through computer-aided design software to generate precise denture models, eliminating the need for manual wax-up and physical model manipulation while maintaining customization capabilities through digital parameter adjustment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates accurate digital copies of the patient's oral cavity through 3D scanning and digital impression taking. These digital models serve as virtual replicas that can be manipulated, measured, and modified without physical contact, enabling rapid iteration and customization while significantly reducing the time required compared to physical model manipulation.

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If physical wax models are used for denture fabrication, then modifications can be made to improve fit, but the process requires multiple attempts and is cumbersome

Engineering Contradiction:

Improvefit precisionVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces physical wax modeling with digital CAD design and 3D printing or CNC milling processes. The digital environment allows for precise control of dimensions and geometry, enabling high manufacturing precision without the trial-and-error nature of physical wax adjustments. The complex process of multiple attempts is reduced to iterative digital modeling and single-step fabrication.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces digital modeling software and manufacturing planning systems as intermediaries between the dentist's requirements and the physical fabrication process. These software tools serve as virtual workshops where precise denture designs can be developed, analyzed, and optimized before actual manufacturing, eliminating the need for multiple physical prototypes and adjustments.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If traditional manufacturing methods are used, then the solid base can be shaped to fit the mouth, but the result causes sore spots and poor retention

Engineering Contradiction:

ImprovecomfortVSAvoidretention

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses digital scanning to capture the exact geometry of the patient's oral tissues and uses CAD software to design the denture base with optimized contact surfaces. This digital approach ensures precise fit to the patient's anatomy, distributing forces evenly and eliminating pressure points that cause sore spots, while maintaining optimal retention through accurately shaped engagement surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If manual denture fabrication is used, then the process can be completed with basic equipment, but it takes two to six weeks and is not user-friendly

Engineering Contradiction:

Improveprocess simplicityVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces manual fabrication processes with automated CAD/CAM systems and digital manufacturing technologies. The entire workflow from digital impression to finished denture can be completed in-house using integrated software and equipment, dramatically reducing production time from weeks to days or even hours while maintaining ease of manufacture through user-friendly software interfaces and streamlined workflows.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11510759B2Modeling and manufacturing the superstructure for a denture

Publication Date: 2022.11.29 3SHAPE AS

AI summary

A system and a method for providing a model of a superstructure joining a denture and a corresponding dental arch, the method includes the steps of obtaining a first 3D representation of at least a part of a preliminary model of the denture, obtaining a second 3D representation of at least a part of the dental arch comprising dental implants, and generating a model of a superstructure based on the first 3D representation, the second 3D representation, dental implant positions and dental implant orientations.