Flexible Partial Denture Additive Manufacturing with Dual-Cure Resin
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Solution Overview
Problem
There is a need for cost-effective and efficient methods to manufacture flexible partial dentures, particularly in a same-day basis, as the demand for these increases.
Innovation Solution
A method involving additive manufacturing using dual cure resins with light and heat polymerizable components, where a partial denture base is produced, acrylic artificial teeth are inserted into sockets, and the assembly is baked to cure the resin, ensuring bonding and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional denture manufacturing methods are used, then manufacturing precision and reliability are maintained, but productivity is low and manufacturing time is long
Solution Approach 1:
The denture manufacturing process is segmented into distinct stages: additive manufacturing of the base with uncured resin, insertion of teeth, and subsequent baking/curing. This segmentation allows parallel processing and eliminates sequential waiting time, significantly improving productivity while maintaining quality standards.
Solution Approach 2:
The denture base is preliminarily manufactured using additive manufacturing with uncured or partially cured resin, allowing teeth to be inserted before final curing. This preliminary action enables same-day manufacturing by preparing the base structure in advance while leaving it in a workable state for tooth insertion.
2Ease of operation
If flexible materials are used for partial dentures, then ease of operation and patient comfort are improved, but manufacturing complexity increases
Solution Approach 1:
The resin's curing parameters are changed during manufacturing - starting with uncured or partially cured state for additive manufacturing and tooth insertion, then transitioning to fully cured state through baking. This parameter change enables the material to be flexible and workable during assembly, then rigid and stable in the final product.
Solution Approach 2:
A dual-cure resin system is used that combines light-curable and heat-curable components. This composite material approach allows the resin to be manipulated in uncured form during manufacturing while providing reliable bonding and structural integrity after complete curing, resolving the conflict between flexibility during assembly and strength in final product.
3Productivity
If additive manufacturing with uncured resin is used, then productivity and same-day manufacturing are achieved, but manufacturing precision and bonding reliability may be compromised
Solution Approach 1:
The manufacturing process maintains continuity by keeping the resin in uncured or partially cured state throughout the additive manufacturing and tooth insertion steps, then completing the curing process in a continuous baking step. This continuous approach ensures proper bonding without interruption, maintaining precision while enabling same-day delivery.
Solution Approach 2:
The curing parameter is changed from partial/uncured state during assembly to fully cured state during baking. This parameter transformation ensures that the resin provides adequate adhesion during tooth insertion while achieving maximum bonding strength and dimensional stability in the final cured product, resolving the precision-reliability concern.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the rapid production of flexible partial dentures with desired tensile properties and bonding, enhancing manufacturing efficiency and cost-effectiveness.
Implementation Method 1
producing a partial denture base by additive manufacturing (e.g., bottom-up or top-down stereolithography) from a dual cure resin, with the dual cure resin comprising a light polymerizable component
Implementation Method 2
baking said assembled intermediate product for a time sufficient to cure said heat polymerizable component in said denture base and the dual cure resin in uncured or partially cured form in said at least one tooth socket
Data Source
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AI summary
Provided herein is a method of making a flexible partial denture, which may include: (a) producing a partial denture base by additive manufacturing (e.g., bottom-up or top-down stereolithography) from a dual cure resin, with the dual cure resin comprising a light polymerizable component and a heat polymerizable component, with the denture base including at least one tooth socket; (b) inserting an acrylic artificial tooth into each at least one tooth socket to produce an assembled intermediate product; and then (c) baking said assembled intermediate product for a time sufficient to cure said heat polymerizable component in said denture base and retained dual cure resin, bond said tooth into each at least one socket with said retained dual cure resin, and produce said flexible partial denture. A flexible partial denture produced and resin formulations useful for the same are also provided.