Digitally Milled Mandibular Splints for Precise Jaw Advancement
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Solution Overview
Problem
Existing mandibular advancement devices face challenges in consistent and precise titration due to manual fabrication methods, leading to durability issues, patient discomfort, and compliance problems, as well as exposure to residual monomers and size limitations.
Innovation Solution
Digitally designed and milled mandibular advancement devices comprising upper and lower splints with fixed fins, allowing for accurate jaw advancement without adjustment screws or straps, using CAD processes and materials like PEEK or acrylate polymers, ensuring precise titration and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual artisanal fabrication methods are used to create mandibular advancement devices, then customization and adaptability to patient anatomy are improved, but manufacturing precision and consistency of titration are worsened
Solution Approach 1:
The patent uses digital scanning to create a precise digital copy of the patient's anatomy, which is then used to manufacture the device with computer-controlled precision. This digital copying process preserves the customization benefits while eliminating the precision limitations of manual fabrication.
Solution Approach 2:
The patent replaces manual mechanical fabrication processes with computer-controlled manufacturing systems. The digital design is transferred to the physical device through automated milling or 3D printing, substituting human skill with computational precision while maintaining patient-specific customization.
2Adaptability or versatility
If adjustment screw mechanisms are used for titration, then adaptability and ease of adjustment are improved, but device complexity and durability are worsened
Solution Approach 1:
The patent creates a dynamic system where the device can be easily adjusted between different advancement settings by simply changing the positioned element, eliminating the need for complex screw mechanisms. The adjustment process is simplified from mechanical manipulation to straightforward repositioning.
Solution Approach 2:
The patent extracts the adjustment function from a complex mechanical screw system and implements it through a simpler positioned element that can be relocated to different predetermined positions. This removes the complexity of threaded mechanisms while preserving the adaptability for titration.
3Adaptability or versatility
If multiple components, straps, and screws are used in device design, then adaptability and adjustability are improved, but reliability and ease of use are worsened
Solution Approach 1:
The patent merges multiple separate components (straps, screws, adjustment mechanisms) into a single integrated positioned element that provides all adjustment functions. This consolidation reduces the number of parts that can fail while maintaining the full range of adaptability needed for titration.
Solution Approach 2:
The positioned element serves multiple functions simultaneously: it provides the mandibular advancement force, enables titration through repositioning, and acts as the primary structural component. This multi-functionality eliminates the need for separate straps and adjustment mechanisms, improving reliability.
4Adaptability or versatility
If manual artisanal fabrication with monomer layering is used, then customization is improved, but patient safety and manufacturing precision are worsened due to residual monomers
Solution Approach 1:
The patent replaces the chemical monomer layering process with computer-controlled material deposition or selective removal. This substitution eliminates the harmful residual monomers associated with traditional acrylic fabrication while preserving the ability to create patient-specific customizations.
Solution Approach 2:
The patent changes the manufacturing parameters from chemical curing of layered monomers to controlled material removal or deposition. This parameter change eliminates the source of residual monomers while maintaining the customization capability through digital design control.
Data Source
AI summary
Disclosed herein are mandibular advancement devices comprising an upper splint and a lower splint, where the upper splint comprises one or more upper fins, where each upper fin is located at a distance UD from back of the upper splint; the lower splints comprise one or more lower fins, where each lower fin is located at a distance LD from back of the lower splint; where the position of the upper and lower fins is unchangeable. Also disclosed are methods of reducing partial constriction of airway during sleep for a patient, the method comprising identifying a patient in need thereof; and administering to the patient the disclosed mandibular advancement device. Also disclosed are methods of manufacturing a mandibular advancement device, the method comprising obtaining measurements from a patient's dentition; digitally designing a mandibular advancement device; and milling the mandibular advancement device.