3D-Printed Orthodontic Aligners with Divot Anchors
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Solution Overview
Problem
Conventional orthodontic aligner manufacturing methods, such as thermoforming, are inefficient, leading to high costs, lengthy treatment times, and discomfort due to inaccurate fitting and material irritation, with limitations in applying torque and rotation control to teeth.
Innovation Solution
Direct 3D-printed orthodontic aligners with torque, rotation, and full-control anchors, utilizing innovative anchoring designs like divot anchors and multi-material properties to apply precise forces for tooth movement, reducing the need for multiple molds and improving fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional thermoforming methods are used to manufacture aligners, then the manufacturing process is well-established and equipment is available, but the process is tedious, costly, and time-consuming requiring multiple molds for different treatment stages
Solution Approach 1:
The patent uses digital 3D models (virtual copies) of the patient's dentition to directly manufacture aligners through additive manufacturing, eliminating the need for physical molds. Each treatment stage is represented by a digital model that can be rapidly printed, replacing the traditional mold-making process entirely.
Solution Approach 2:
The patent changes the manufacturing approach from subtractive/thermal processes (thermoforming) to additive manufacturing (3D printing). This fundamental parameter change enables direct fabrication of aligners from digital models, dramatically reducing the number of steps and eliminating mold storage requirements.
2Ease of manufacture
If conventional thermoforming is used to create attachment apertures, then the process is simple, but the aperture shapes are limited and aligners bind with attachments making removal difficult
Solution Approach 1:
The patent changes the aperture formation method from thermal stretching (thermoforming) to direct additive manufacturing. This enables apertures to be printed with precise geometries including irregular shapes, variable thicknesses, and complex internal structures that cannot be achieved through thermoforming.
Solution Approach 2:
The patent segments the aperture structure into multiple components including the aperture itself, surrounding reinforcement structures, and attachment engagement features. This segmentation allows each element to be optimized independently for both manufacturing ease and functional performance.
3Manufacturing precision
If conventional aligners are trimmed to fit the gingiva, then the aligner can be made to size, but sharp edges are created that irritate the gingiva and cause discomfort
Solution Approach 1:
The patent performs preliminary smoothing of the aligner edges during the 3D printing process itself, incorporating rounded edges and fillets into the printed geometry. This preliminary action eliminates the need for post-manufacturing trimming that would create sharp edges, and the smoothing effect is built-in before the aligner contacts the patient's tissues.
Solution Approach 2:
The patent changes the edge geometry parameters directly in the digital model before printing, specifying rounded corners and filleted edges with precise radii. This parameter change ensures that the printed aligner has inherently smooth edges that conform to the gingiva without causing irritation.
4Force
If conventional aligners are used, then the treatment can proceed, but the aligners cannot effectively apply torque and rotation control forces to teeth
Solution Approach 1:
The patent applies local quality by creating regions of varying thickness and material density within the aligner structure. Thicker regions with higher material concentration are positioned to apply torque and rotation forces, while thinner regions provide flexibility. This localized variation in structural properties enables precise force application without requiring a completely complex overall design.
Solution Approach 2:
The patent uses composite materials with different mechanical properties within the same aligner structure. Regions requiring high force application use stiffer, stronger materials, while regions requiring flexibility use softer, more compliant materials. This composite approach enables the aligner to simultaneously provide torque control, rotation control, and comfortable fit.
Data Source
AI summary
Direct 3D-printed orthodontic aligners with torque, rotation, and full-control anchors divots are provided. An example process generates multiple virtual models of orthodontic treatment based on progressive moduli of elasticity (MOE) of different materials that will be used to 3D-print a progressive set of 3D-printed aligners. A progression of 3D-printed aligners applies modeled forces to the divot anchors positioned by the models and to the teeth, in treatment stages that are also computed by the models. One class of the example 3D-printed aligners may have flat occlusal biting surfaces, enabling simultaneous treatment of bite correction, temporomandibular joint disorder (TMD), lower jaw growth, and sleep apnea, along with orthodontic movement of teeth. An example 3D-printed aligner has a micro blower for creating air pressure to treat apnea. The aligner may have a microprocessor, sensors, data handling, and data transmission, for controlling actions of the 3D-printed aligner.