Layered Denture Manufacturing with Inverted Sequence and Segmented Roots

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional denture manufacturing methods fail to adequately address aesthetics and function, particularly in mimicking natural tooth structure and maintaining enamel strength, as they lack anatomical roots and require grinding that weakens the denture.

Innovation Solution

A method for manufacturing layered dentures by machining a material blank to form cavities, filling with different materials to create layers that simulate roots and reinforce the enamel layer, using CAD/CAM technology and 3D digital images for balanced occlusion and realistic appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional denture teeth are made using injection molding or pressure molding techniques, then manufacturing is simplified and cost is reduced, but anatomical roots cannot be incorporated and aesthetic appearance below the gum line is compromised

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidanatomical root structure

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The denture tooth is divided into multiple layers: an enamel layer, a dentin layer, and a root structure. Each layer is manufactured separately using different techniques (maching for enamel, molding for dentin and root) and then bonded together, allowing anatomical root structures to be incorporated while maintaining manufacturing efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The denture tooth structure is constructed with nested layers where the root structure forms the base, the dentin layer is positioned over the root, and the enamel layer caps the top. This nested arrangement creates realistic anatomical root structures that extend into the denture base while maintaining ease of manufacture through sequential assembly

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of manufacture

If the denture base is machined first followed by the teeth in traditional manufacturing, then the base structure is established, but the enamel layer experiences the greatest wear yet is formed last and may not be sufficiently strengthened

Engineering Contradiction:

Improvemanufacturing sequenceVSAvoidenamel layer strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The manufacturing sequence is inverted so that the enamel layer is formed first as the foundation, followed by the dentin layer, and finally the root structure. This reversal ensures the enamel layer, which experiences the greatest wear, is established first and can be optimized for strength before subsequent layers are added

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If denture teeth are ground to achieve balanced occlusion, then the denture remains stable during mandible movement, but the enamel layer is removed and teeth are weakened

Engineering Contradiction:

Improveocclusal balanceVSAvoidenamel integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Balanced occlusion is built into the tooth design during the manufacturing process itself, rather than requiring subsequent grinding. The enamel layer is machined with precise occlusal surfaces that achieve balanced contact points during mandible movement, eliminating the need for post-manufacturing grinding and preserving enamel integrity

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10251733B2System and method for manufacturing layered dentures

Publication Date: 2019.04.09 GLOBAL DENTAL SCIENCE LLC

AI summary

A method of manufacturing a layered denture in which the enamel layer or the tooth layer is manufactured first and the denture base is manufactured last. The resulting denture may exhibit an enamel layer or a tooth layer with enhanced strength and/or resiliency. The resulting denture may have one or more of an integrated layer, balanced occlusion, and a root approximating structure.