Laser Sintering Dental Implant Abutments
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Solution Overview
Problem
The conventional manufacturing process of dental implant abutments is laborious and costly due to the need for manual finishing and the production of customized main bodies, which requires significant manual work.
Innovation Solution
The method involves forming the main body of the implant abutment by sintering or melting powdery material onto a prefabricated base member using laser sintering or laser melting, allowing for automated production and precise, cost-effective manufacturing with the option of ceramic coating for improved esthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional modeling and casting methods are used to manufacture implant abutments, then customized main bodies can be produced, but the process becomes laborious and costly requiring significant manual finishing work
Solution Approach 1:
The patent replaces the conventional mechanical modeling and casting process with a laser-based additive manufacturing system. The laser melts and sinter powdery material directly onto the base member according to digital models, eliminating the need for physical wax modeling, mold making, and manual casting operations. This substitution of mechanical processes with optical/thermal processes directly resolves the contradiction by maintaining precision while dramatically improving productivity.
Solution Approach 2:
The patent changes the physical state and form of material delivery from pre-formed wax models and molds to powdery material that is selectively melted and sintered by laser. This parameter change in material delivery form enables automated layer-by-layer construction, resolving the contradiction between precision customization and production efficiency.
2Ease of manufacture
If conventional casting methods are used, then implant abutments can be manufactured, but extensive manual finishing work is required
Solution Approach 1:
The laser-based additive process replaces conventional casting and manual finishing operations. The laser directly melts and sinteres material to build the exact final geometry, eliminating the need for post-casting finishing operations. This substitution resolves the contradiction by simplifying the manufacturing process while eliminating time-consuming manual work.
Solution Approach 2:
The additive manufacturing process performs preliminary action by building the component with its final geometry and surface finish directly during the manufacturing process itself, rather than requiring subsequent finishing operations. The laser melting and sintering process creates the final surface in-place, resolving the contradiction between ease of manufacture and time loss.
3Productivity
If standardized base members are used for implant abutments, then production cost decreases and quality optimizes, but customization of the main body is limited
Solution Approach 1:
The patent segments the implant abutment into two distinct parts: a standardized base member that can be mass-produced, and a customized main body that is additively manufactured. This segmentation allows the base member to be produced efficiently in large quantities while the main body can be fully customized for each patient, resolving the contradiction between production volume and customization capability.
Solution Approach 2:
The patent merges the standardized base member with the customized main body through direct laser melting and sintering of material onto the base member surface. This merging creates a fully integrated component that combines the advantages of standardized production with customized adaptation, resolving the contradiction between productivity and adaptability.
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 efficient, automated production of precision implant abutments with reduced manual labor, improved precision, and enhanced esthetic appearance through ceramic coating, simplifying the production process and reducing costs.
Implementation Method 1
the main body is formed by sintering and/or melting powdery material onto the base member using laser sintering and/or laser melting
Implementation Method 2
the main body is formed by sintering and/or melting powdery material onto the base member using laser sintering and/or laser melting
Data Source
AI summary
The invention relates to a method for manufacturing implant abutments 9 for dental implants 1, wherein the implant abutment 9 comprises a prefabricated base member 8 for joining the implant abutment to the dental implant 1, and a customized main body 15. The aim of the invention is to simplify this method of manufacturing. To this end, the main body 15 is formed by sintering and/or melting powdery material onto the base member 8 using laser sintering and/or laser melting. The invention relates also to an implant abutment manufactured by such a method.