Duplicate Orthodontic Aligners for Early Deviation Detection

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Solution Overview

Problem

Barriers to widespread use of orthodontic treatment options exist, particularly for dental practitioners with limited experience, due to challenges in detecting deviations from planned treatment courses, which can lead to variability in treatment outcomes and decreased efficacy.

Innovation Solution

Systems and methods for managing orthodontic treatment planning and delivery, including customized treatment guidelines and progress tracking features, tailored to individual patients, to facilitate orthodontic practice among a range of practitioners, with features such as appointment planning tools and enhanced detection of deviations from planned treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If practitioners with limited experience provide orthodontic treatment, then access to treatment is improved, but treatment reliability and predictability deteriorate due to inability to detect deviations from planned treatment

Engineering Contradiction:

Improveaccess to treatmentVSAvoidtreatment reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system implements automated feedback mechanisms by comparing actual tooth positions (from progress scans) against the planned treatment trajectory. This continuous monitoring provides practitioners with objective data about treatment progression, enabling even less experienced practitioners to detect deviations early and maintain treatment reliability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual visual inspection and subjective clinical judgment with automated digital imaging and computerized analysis systems. This substitution of mechanical/manual processes with automated systems enables consistent, objective detection of treatment deviations regardless of practitioner experience level.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If treatment progresses without monitoring, then treatment speed is improved, but detection of deviations is delayed leading to decreased treatment efficacy

Engineering Contradiction:

Improvetreatment speedVSAvoiddeviation detection precision

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system performs preliminary actions by establishing the planned treatment trajectory in advance and using it as a reference framework. During treatment progression, actual positions are continuously compared against this pre-established plan, enabling early detection of deviations before they become significant problems.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback loops where progress scans are automatically analyzed and compared against the treatment plan. This real-time or near-real-time feedback enables practitioners to detect deviations promptly while maintaining efficient treatment progression, resolving the conflict between speed and detection precision.

Inventive Principle:

Principle #23Feedback

3Device complexity

If conventional monitoring methods are used, then device complexity is minimized, but measurement precision of treatment progression deteriorates

Engineering Contradiction:

Improvemonitoring system complexityVSAvoidtreatment progression measurement precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces simple visual inspection methods with automated digital imaging and computerized analysis. This substitution introduces more sophisticated technology that dramatically improves measurement precision of treatment progression while managing complexity through automation and standardized protocols.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates digital copies (scans) of the patient's actual tooth positions and compares these copies against the digital treatment plan. This copying approach enables precise, objective measurement of treatment progression without requiring complex manual measurement techniques.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS12491048B2Systems and methods for orthodontic treatment with duplicate appliances

Publication Date: 2025.12.09 ALIGN TECHNOLOGY INC

AI summary

Systems and methods for moving teeth of a patient from a first tooth arrangement toward a second tooth arrangement are provided, including: a first dental appliance corresponding to a first stage of an orthodontic treatment plan and corresponding to the first tooth arrangement; a second dental appliance corresponding to a second stage of the orthodontic treatment plan and corresponding to the second tooth arrangement; and a plurality of intermediate dental appliances corresponding to a plurality of intermediate stages between the first stage and the second stage of the orthodontic treatment plan. The intermediate dental appliances include a first intermediate dental appliance having first tooth receiving cavities shaped for moving the patient's teeth as prescribed for the respective intermediate stage by the orthodontic treatment plan, and a duplicate intermediate dental appliance having duplicate tooth receiving cavities with the same geometries as the first tooth receiving cavities.