Integrated Orthodontic Tray with Monolithic Brackets
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Solution Overview
Problem
Current methods for producing positioning trays with individual brackets are time-consuming and costly, and the indirect bonding of brackets using positioning splints can lead to detachment issues and excess adhesive residue, complicating the orthodontic treatment process.
Innovation Solution
A method for manufacturing a positioning tray with brackets directly physically connected to a positioning aid in a one-step process using generative or ablative manufacturing, where initial data on tooth geometry is recorded and virtually planned to create a coherent tray with brackets and positioning aid, allowing for precise positioning and attachment to teeth without the need for separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If positioning trays are produced using indirect bonding methods with separate components, then the brackets can be positioned on teeth, but the production process becomes time-consuming and costly
Solution Approach 1:
The patent combines the positioning aid and brackets into a single integrated positioning tray component. This merging eliminates the need for separate production and assembly steps for positioning aids and brackets, thereby simplifying the manufacturing process and reducing production time while maintaining precise positioning capability.
2Ease of operation
If indirect bonding using positioning splints is used, then brackets can be transferred to teeth, but detachment issues and excess adhesive residue occur
Solution Approach 1:
By integrating the positioning aid and brackets into one piece, the invention eliminates the interface between separate components that causes adhesive residue and detachment problems. The unified structure ensures reliable bonding directly to the tooth surface without the complications of transferring brackets from a separate positioning splint.
3Ease of manufacture
If standardized brackets are used, then manufacturing is simplified, but adaptation to individual patient anatomy becomes difficult
Solution Approach 1:
The invention enables customization of the positioning tray by varying geometric parameters such as the shape, size, and position of brackets relative to the positioning aid. This allows adaptation to individual patient anatomy through digital modeling and additive manufacturing while maintaining the manufacturing efficiency of standardized components.
Solution Approach 2:
The positioning tray is customized in advance through digital planning and additive manufacturing based on patient-specific anatomy. This preliminary customization allows the tray to be optimally adapted to the patient's teeth before the bonding procedure, combining patient-specific adaptation with efficient manufacturing.
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 production time and errors, simplifies the process, and enhances the accuracy and flexibility of orthodontic treatments by allowing for on-site customization and easier replacement of positioning trays, improving patient comfort and treatment efficiency.
Implementation Method 1
A method for manufacturing a positioning tray with brackets directly physically connected to a positioning aid in a one-step process using generative or ablative manufacturing
Data Source
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AI summary
The present invention relates to a method for producing a positioning tray for brackets of dental braces, wherein the positioning tray has a positioning aid and one or more associated brackets, wherein the positioning aid is formed as one piece with the associated bracket(s), comprising the following steps: obtaining original data which describe the present geometry of one or more teeth of at least one jaw of a patient; obtaining target data which describe the geometry of the one or more teeth of the at least one jaw of the patient after treatment with dental braces; calculating tray configuration data which describe the geometry of brackets with respect to the present geometry of the one or more teeth of the at least one jaw of the patient and the positioning aid arising from the original data and the target data, wherein the calculation of the tray configuration data is carried out such that using the described brackets of this type, the positioning aid is connected such that it can be used in order to position the brackets with respect to the teeth of the patient such that the bracket(s) can be connected to the surface of the teeth of the patient, and that, together with an ideal curve (basis for planning), previously determined and to be connected to (one of) the bracket(s), a correction of a malocclusion can be carried out; producing, on the basis of the tray configuration data, a corresponding positioning tray through a generative or ablative manufacturing method. The invention further relates to a corresponding device, a computer-readable storage medium and a corresponding positioning tray.