Dual-Mode Intraoral Scanner With Dynamic Focus for Face Capture

Solution Overview

Problem

Existing methods do not allow for concurrent or sequential scanning of a subject's face and intraoral cavity with precision and ease in a single platform, which is crucial for accurate dental and orthodontic procedures.

Innovation Solution

An intraoral scanner with a wand that can switch between intraoral and facial scanning modes using a first and second optical path, where the second path extends the depth of focus to accommodate facial scanning, and a removable sleeve with additional optical components for facial scanning, allowing integration of 2D/3D data from both areas into a unified patient-specific data structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a single intraoral scanner platform is used for both intraoral and facial scanning, then device complexity is reduced and ease of operation is improved, but the depth of focus cannot simultaneously accommodate both intraoral (2-40 mm) and facial (20-200 mm) scanning ranges

Engineering Contradiction:

Improveease of operationVSAvoiddepth of focus

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The optical system incorporates a dynamic depth of focus adjustment mechanism that allows the focal plane to be moved between two positions: one optimized for intraoral scanning (2-40 mm) and another for facial scanning (20-200 mm). This dynamic adjustment enables a single platform to adapt its focusing characteristics based on the scanning task, resolving the contradiction between maintaining precise depth of focus for different applications and using a unified device.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The intraoral scanner is designed with multi-functionality to perform both intraoral cavity scanning and facial scanning using the same optical path and sensor system. By integrating facial scanning capability into the existing intraoral scanner platform, the device achieves universal application, reducing the need for multiple separate devices while maintaining scanning precision through the dynamic focus adjustment feature.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If separate devices are used for intraoral and facial scanning, then scanning precision for each specific application is optimized, but device complexity increases and treatment planning efficiency decreases

Engineering Contradiction:

Improvescanning precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the functions of separate intraoral scanner and facial scanner into a single unified platform. The same optical system, sensor array, and data processing infrastructure are used for both scanning applications. This consolidation reduces device complexity and eliminates the need for multiple separate devices while maintaining scanning precision through the dynamic depth of focus capability that optimizes performance for each specific scanning task.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If the intraoral scanner uses a fixed optical path optimized for intraoral scanning, then intraoral scanning precision is maintained, but the scanner cannot capture facial data without additional optical components

Engineering Contradiction:

Improveintraoral scanning precisionVSAvoidadaptability

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The optical system incorporates a dynamic depth of focus adjustment mechanism that allows the focal plane to be moved between two positions: one optimized for intraoral scanning (2-40 mm) and another for facial scanning (20-200 mm). This dynamic adjustment enables a single platform to adapt its focusing characteristics based on the scanning task, resolving the contradiction between maintaining precise depth of focus for different applications and using a unified device.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The intraoral scanner is designed with multi-functionality to perform both intraoral cavity scanning and facial scanning using the same optical path and sensor system. By integrating facial scanning capability into the existing intraoral scanner platform, the device achieves universal application, reducing the need for multiple separate devices while maintaining scanning precision through the dynamic focus adjustment feature.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates streamlined treatment planning and design by integrating facial and intraoral data without additional devices, enhancing the accuracy and efficiency of dental and orthodontic treatments.

Implementation Method 1

Any appropriate scanning modality may be used, including confocal, structured light, etc.

Methodology Applied

Scientific EffectStructured light:

Implementation Method 2

The subject's intraoral cavity is typically scanned to form a 3D model (e.g., a digital 3D model) of the intraoral cavity; the subject's face may be scanned to form one or more 2D images and/or in some variations a 3D image

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS12496171B2Face capture and intraoral scanner and methods of use

Publication Date: 2025.12.16 ALIGN TECHNOLOGY INC

AI summary

Apparatuses (e.g., systems, devices, etc.) and method for scanning both a subject's face as well as the subject's intra oral cavity to provide two-dimensional (2D) and/or three dimensional (3D) data that may be subsequently used in prosthodontic and orthodontic procedures, including smile planning (e.g., designing or modifying a subject's overall smile or facial aesthetics).