3D-Printed Intraoral Cellular Structures for Precise Orthodontic Force

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Solution Overview

Problem

Conventional intraoral appliances often lack sufficient force generation and control over applied forces, providing linear strain profiles with limited elasticity, leading to inadequate tooth repositioning and increased patient discomfort.

Innovation Solution

Intraoral appliances with adaptive cellular materials and structures that offer controlled mechanical properties, including non-linear force/strain profiles, customizable for individual patients, utilizing heterogeneous and homogeneous cellular structures with varying Young's moduli and elongation rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If conventional homogeneous materials are used in intraoral appliances, then manufacturing is simple, but force generation and control are insufficient

Engineering Contradiction:

Improveforce generationVSAvoidmaterial structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating intraoral appliances with spatially varying cellular structures. Different regions of the appliance have different unit cell geometries, sizes, and densities, allowing each region to provide optimized mechanical properties. This enables precise control over force distribution across different areas of the appliance, resolving the contradiction between simple manufacturing and sufficient force control.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining cellular structures with polymeric materials to create hybrid structures. The cellular architecture provides enhanced mechanical properties including controlled elasticity and force generation, while the polymeric material provides biocompatibility and flexibility. This composite approach enables superior force generation compared to conventional homogeneous materials.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If conventional linear strain profile materials are used, then material selection is simple, but elasticity and elongation control are limited

Engineering Contradiction:

Improveelasticity controlVSAvoidstrain profile

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by systematically varying cellular structure parameters including unit cell geometry, size, wall thickness, and density distribution. These parameter variations enable continuous tuning of mechanical properties such as elasticity, elongation rate, and force-strain relationships. The ability to independently adjust multiple parameters provides versatile elasticity control while maintaining manufacturability through additive manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If cellular materials with small unit cells are used, then mechanical property control is enhanced, but fabrication difficulty and cost increase

Engineering Contradiction:

Improveunit cell size controlVSAvoidfabrication process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical fabrication methods with additive manufacturing (3D printing) technology. This substitution enables precise control over small unit cell dimensions and complex cellular geometries that would be difficult or impossible to manufacture using conventional techniques. Additive manufacturing allows for layer-by-layer construction with high precision, resolving the contradiction between manufacturing precision and ease of manufacture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances orthodontic treatment effectiveness by providing precise force application, reducing discomfort, and extending appliance lifetime through controlled mechanical properties and customizable designs.

Implementation Method 1

The first network of interconnected unit cells having a first elongation characteristic, the first elongation characteristic being characterized by a first elongation value

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250359967A1Additively manufactured appliances with cellular structures

Publication Date: 2025.11.27 ALIGN TECHNOLOGY INC

AI summary

Intraoral appliances and associated systems are provided. In some embodiments, an intraoral appliance includes a 3D printed body composed of a plurality of additively manufactured layers. The 3D printed body can include a first cellular structure located at one or more first areas of the intraoral appliance, the first cellular structure corresponding to a first stiffness, and a second cellular structure located at one or more remainder areas of the intraoral appliance, the second cellular structure corresponding to a second stiffness less than the first stiffness.