Orthodontic Aligner Trimline Definition Using Gingival Margin Points
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Solution Overview
Problem
The manufacturing of orthodontic aligners is hindered by difficulties in trimming excess material due to complex shapes and small sizes of human dentition, leading to time-consuming manual processes and limitations with CNC milling, which often results in suboptimal performance and prolonged treatment.
Innovation Solution
A computer-implemented method and system for defining a trimline in a 3-D digital model of teeth, generating machine code for manufacturing aligners, and using CNC machinery to cut the trimline, allowing for precise edge configuration and reducing the need for manual modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trimming with scissors is used, then the aligner can be trimmed to complex shapes, but the process is time consuming and requires significant skill
Solution Approach 1:
The patent replaces manual mechanical trimming with scissors with an automated CNC milling machine that uses computer-controlled cutting tools. The system converts digital trimline designs into automated machining operations, eliminating the need for manual skill while maintaining precision and significantly reducing trimming time.
Solution Approach 2:
The patent creates a digital copy of the desired trimline geometry in computer-aided design (CAD) software before manufacturing. This digital model serves as a precise template that guides the CNC milling process, ensuring accurate reproduction of complex shapes without requiring manual measurement or estimation.
2Extent of automation
If CNC milling is used, then trimming automation is achieved, but the setup procedure is complicated and expensive
Solution Approach 1:
The patent designs the CNC milling setup to handle multiple aligner types and trimline configurations using the same basic equipment and procedures. The system can process different tooth models, gingival margins, and trimline styles without requiring separate specialized tools or complex reconfiguration, making the automation universally applicable.
Solution Approach 2:
The patent performs all trimline design, toolpath generation, and machining parameter optimization in advance using computer software before the actual manufacturing begins. This preliminary digital preparation eliminates the need for complex on-site setup adjustments and allows the physical CNC process to proceed with simple, pre-determined parameters.
3Productivity
If CNC milling is used, then trimming speed increases, but certain percentage of aligners cannot be completely separated due to spatial limitations
Solution Approach 1:
The patent divides the trimming process into multiple sequential operations or stages. For complex aligners that cannot be separated in a single pass, the system performs multiple cutting passes with different toolpaths, gradually removing material until complete separation is achieved. This segmented approach overcomes spatial limitations of the milling tool.
Solution Approach 2:
The patent utilizes multi-axis CNC milling capabilities to approach and cut the aligner material from different spatial dimensions and angles. By moving the cutting tool in three-dimensional space rather than being constrained to a single plane, the system can access difficult-to-reach areas and complete separations that would be impossible with two-dimensional cutting only.
4Adaptability or versatility
If manual field modifications are made to aligners, then clinician preferences can be accommodated, but the resultant aligner has less than optimum performance and treatment is prolonged
Solution Approach 1:
The patent allows clinicians to make all desired modifications to the trimline design in the computer-aided design phase before manufacturing begins. Any customizations for patient-specific needs or clinician preferences can be incorporated into the digital model and then automatically manufactured with high precision, eliminating the need for subsequent manual field modifications that would compromise performance.
Data Source
AI summary
Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.