Intraoral Splint Design via Thermal Segmentation
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Solution Overview
Problem
Current methods for designing intraoral devices, such as mandibular splints, using CAD/CAM technology result in devices with uniform thickness that require laborious manual adjustments, leading to inaccuracies and discomfort for patients, as they do not allow for precise control over individual dental pieces or non-uniform thicknesses.
Innovation Solution
The method involves segmenting dental arches into individual pieces using thermal simulation, assigning heat points, and defining local vectors and centroids to create a personalized design with non-uniform thicknesses, allowing for precise control over the splint's contour and internal forces, thereby enhancing patient comfort and treatment efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform thickness mesh design is used for intraoral devices, then manufacturing process is simplified, but manufacturing precision and patient comfort deteriorate due to inability to control local thickness and contact areas
Solution Approach 1:
The patent segments the dental arch mesh into multiple independent dental pieces (individual teeth or tooth groups) rather than treating it as a single uniform structure. This segmentation allows each dental piece to have independently controlled thickness and geometry, enabling precise local customization while maintaining compatibility with automated 3D printing manufacturing processes.
Solution Approach 2:
The patent implements local quality by allowing different regions of the intraoral device to have different thickness values and material properties. Each dental piece can be designed with specific thickness characteristics tailored to its functional requirements, such as thinner regions for comfort and thicker regions for structural support, thereby achieving high manufacturing precision without compromising ease of manufacture.
2Productivity
If uniform thickness mesh is used for 3D printing, then printing process is simplified, but device accuracy and comfort worsen due to lack of personalized adaptation to individual dental pieces
Solution Approach 1:
By dividing the dental arch into separate dental pieces, the patent enables personalized adaptation to each tooth or tooth group while maintaining efficient 3D printing. The segmented structure allows the printing process to follow simple paths for each piece independently, preserving productivity while achieving high device accuracy through customized geometry for each dental piece.
Solution Approach 2:
The patent performs preliminary design and adaptation of each dental piece's geometry and thickness before the 3D printing process. This preliminary action ensures that each piece is precisely customized to fit the patient's specific dental anatomy, achieving high measurement precision and comfort while the actual printing process remains efficient and automated.
3Adaptability or versatility
If manual adjustments are performed after printing, then device personalization can be improved, but time consumption and labor increase significantly
Solution Approach 1:
The patent performs all necessary personalization and adaptation actions during the digital design phase before 3D printing. Each dental piece is precisely customized to the patient's anatomy in advance, eliminating the need for time-consuming manual adjustments after printing. This preliminary action achieves high adaptability while minimizing time loss.
Solution Approach 2:
The patent enables the intraoral device to be self-adapted to the patient's dental arch through its segmented design. Each dental piece naturally conforms to its corresponding tooth or region due to the customized geometry designed in advance, reducing or eliminating the need for manual intervention and significantly decreasing adjustment time.
4Manufacturing precision
If segmented dental pieces design is implemented, then manufacturing precision and patient comfort improve, but device complexity increases
Solution Approach 1:
While segmentation does increase design complexity by dividing the dental arch into multiple pieces, the patent manages this complexity through automated digital workflows and algorithms that systematically generate and coordinate the geometry of each piece. The segmentation enables high manufacturing precision and patient comfort, and the complexity is offset by the efficiency gains in customization and reduced manual intervention.
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 enables the creation of highly personalized, precise intraoral devices that minimize manual adjustments and improve patient comfort by allowing for customized thickness and material distribution, effectively treating conditions like bruxism and sleep apnea.
Implementation Method 1
Thermal simulation consists of assigning heat points of one temperature to dental pieces and heat points of a different temperature to the dental pieces adjacent to the dental pieces with heat points of the first temperature. In this way, adjacent dental pieces have different heat points. Once the heat points have been assigned to all the dental pieces by means of the CAD software, a thermal simulation is carried out by conduction, so that since heat is not transmitted between adjacent dental pieces as they are at different temperatures, all the dental pieces are defined separately.
Data Source
AI summary
Design method of an intraoral splint-type device (1) to treat bruxism and/or sleep apnoea among others, using CAD/CAM software technology, where the method of the invention starts with an intraoral scan and is subsequently characterized by converting the arch (2, 3) defined as a one-piece mesh, into as many pieces as dental pieces (4) needed to be discerned, by means of thermal simulation. This segmentation makes it possible to isolate the geometry of each dental piece (4) in order to design the intraoral device (1) around each dental piece (4). In other words, it allows for the modification of the thickness (6c), height, etc. in a non-uniform way for each dental piece (4) according to the needs of the patient. This method allows the user very precise manipulation of the intraoral device (1) that is created, satisfying the mechanical and dental needs of each dental piece (4), and providing greater comfort to the patient.