Hybrid Denture Fabrication Using Digital Workflow
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Solution Overview
Problem
Conventional hybrid denture fabrication is time-consuming, requiring 6-8 months from patient surgery to delivery, involving extensive patient chair-time and multiple office visits, with the need for temporary dentures.
Innovation Solution
The systems and methods utilize a fully-digital process involving 3D scanning, computer-aided design, and milling to fabricate a permanent hybrid prosthesis within 24 hours, eliminating the need for temporary dentures and reducing patient visits by using a 3D scanner, computing device, and milling machine to create a custom-milled bridge and reinforcing bar with a precise fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hybrid denture fabrication methods are used, then the denture can be fabricated with traditional techniques, but the process requires 6-8 months from surgery to delivery and extensive patient chair-time
Solution Approach 1:
The patent replaces conventional mechanical denture fabrication methods with a digital workflow. A 3D scanner captures patient anatomy, creating a digital model that is processed through CAD software to design the hybrid denture. The denture is then fabricated using a milling machine that mills the denture from a block of material based on digital instructions, eliminating the need for traditional impression taking, wax-ups, and manual laboratory techniques.
Solution Approach 2:
The patent changes the fundamental parameters of the fabrication process by transitioning from analog to digital methods. The 3D scanning process captures precise anatomical data in digital format, allowing for accurate replication of patient anatomy. The digital design process enables precise control of denture parameters, and the milling process uses computer-controlled parameters to achieve high precision fabrication within 24 hours.
2Ease of operation
If conventional fabrication processes are used, then temporary dentures can be provided to patients, but multiple office visits and adjustments are required
Solution Approach 1:
The patent performs preliminary actions by capturing the complete patient anatomy through 3D scanning before surgery, and then using digital planning to design the final hybrid denture before fabrication. This allows the definitive denture to be customized and fabricated in advance, eliminating the need for temporary dentures and multiple adjustment visits. The digital workflow enables all necessary measurements and designs to be completed prior to the final delivery appointment.
3Reliability
If traditional denture fabrication is used, then the process can accommodate standard procedures, but patient chair-time totals approximately 15 hours
Solution Approach 1:
The patent replaces time-consuming manual procedures with automated digital systems. The 3D scanner rapidly captures patient anatomy in minutes rather than hours. The CAD software automatically processes the scan data and generates the denture design, eliminating manual measurement and drawing time. The milling machine fabricates the denture with high precision in 24 hours without requiring repeated patient visits for adjustments, reducing total chair-time while maintaining or improving fit quality.
Data Source
AI summary
Described herein is a system for hybrid denture fabrication. The system improve the efficiency of the fabrication process for both the dental service provider (e.g., dentist, dental surgeon, etc.) and the patient. A permanent hybrid prosthesis (e.g., the bridge and its reinforcing bar) can be fabricated within 24 hours of the surgical procedure using the system described herein. This makes it possible to deliverer the permanent hybrid prosthesis within 48 hours (or even within 24 hours) of the surgical procedure. Additionally, the system eliminates the need to provide the patient with a temporary denture following the surgery. Further, the system substantially reduces the patient's chair-time and/or the number of patient visits.