Indirect Bonding Tray Wells for Orthodontic Bracket Accuracy
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Solution Overview
Problem
Existing indirect bonding systems for orthodontic bracket placement often suffer from human error in bracket placement on physical models, leading to inaccuracies in the indirect bonding tray and ultimately on the patient's teeth.
Innovation Solution
The method involves creating a physical model of a patient's teeth with non-functional placeholder orthodontic brackets, which are optimized for indirect transfer methods. A moldable material is applied over the model to create an indirect bonding tray with wells corresponding to the placeholder brackets. Functional orthodontic brackets with the same external geometry are then secured within these wells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If functional orthodontic brackets are manually transferred from a physical model to the indirect bonding tray, then the process allows for initial positioning and adjustment, but human error occurs leading to placement inaccuracies
Solution Approach 1:
The indirect bonding tray is pre-formed with wells that exactly match the external geometry of the orthodontic brackets before the brackets are placed. This preliminary preparation of the receiving structure eliminates the need for manual positioning and transfer adjustments, ensuring that brackets are seated in their correct positions directly during the bonding process.
Solution Approach 2:
The indirect bonding tray is created as a precise negative copy or impression of the physical model with placeholder brackets. The moldable material captures the exact geometry and position of each placeholder bracket, creating a replica structure that transfers the bracket positions accurately to the patient's teeth without manual intervention.
2Productivity
If multiple transfer steps are used from physical model to indirect bonding tray to patient's teeth, then flexibility in adjustment is provided, but the number of steps increases leading to accumulated errors
Solution Approach 1:
The invention merges the functions of the physical model, placeholder brackets, and indirect bonding tray into a single integrated transfer system. The placeholder brackets are permanently attached to the physical model, and the indirect bonding tray is formed as one piece that captures all bracket positions simultaneously, eliminating the need for separate transfer steps and reducing cumulative errors.
Solution Approach 2:
The system segments the bracket placement process into two distinct phases: (1) creating the indirect bonding tray with wells that match placeholder bracket geometry, and (2) transferring the tray directly to the patient's teeth. This segmentation allows for precise replication of bracket positions in the tray while streamlining the transfer step to a single direct application.
3Ease of manufacture
If placeholder brackets with complex internal geometries are used, then functional features are preserved, but the molding process becomes difficult and tray fabrication is compromised
Solution Approach 1:
The placeholder brackets are designed to have only the essential external geometry required for accurate bracket positioning, while removing complex internal geometries such as undercuts and wire engagement features. This extraction of unnecessary complexity allows the moldable material to easily capture the bracket positions and shapes without being hindered by difficult-to-mold internal structures.
Solution Approach 2:
The placeholder brackets possess different properties in different regions: the external surfaces that contact the moldable material have smooth, undercut-free geometries optimized for molding, while the bonding surfaces and internal structures are designed separately to ensure accurate bracket attachment and position transfer. Each region of the placeholder bracket is optimized for its specific function in the transfer process.
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 reduces the likelihood of human error in bracket placement, as the functional brackets are directly seated on the indirect bonding tray without initial transfer from a physical model, thereby enhancing the accuracy and efficiency of orthodontic bracket placement.
Implementation Method 1
A moldable material is applied over the teeth and at least one placeholder bracket of the physical model, thereby creating an indirect bonding tray
Implementation Method 2
The moldable material can be cured, and include, for example, polyvinyl siloxane
Data Source
AI summary
Systems and methods for fabricating indirect bonding trays are disclosed. Physical models of a patient's teeth can be created with non-functional placeholder brackets, impressions of which can be transferred to indirect bonding trays. This can create wells in which functional brackets can be placed into, reducing errors created from transferring functional brackets from the physical model onto the indirect bonding trays.