Layered Lithium Silicate Dental Restoration Production
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Solution Overview
Problem
Existing methods for producing dental restorations from lithium silicate glass ceramics require additional heat treatment steps and struggle to achieve desired coloration and translucency without complexity.
Innovation Solution
A method involving multiple layers of powders derived from different lithium silicate glass compositions, where the surface of one layer is structured to vary in height and the second layer is filled with a differing composition, allowing for mixing and pressing to achieve continuous optical transitions, eliminating the need for further heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple layers of powders with different compositions are filled into a mold layer-by-layer to achieve desired coloration and translucency, then the optical properties of the dental restoration are improved, but the device complexity and manufacturing process become more complex
Solution Approach 1:
The dental restoration is divided into multiple layers of powders with different compositions during the forming process. Each layer contains specific glass compositions (e.g., lithium silicate glass with different metal oxide contents) that provide different optical properties. This segmentation allows control of translucency and coloration in different regions of the restoration without requiring complex post-processing heat treatment steps.
Solution Approach 2:
The desired optical properties are built into the restoration during the initial forming process by pre-mixing powders with different compositions in specific layers. The coloration and translucency gradients are established beforehand through the layer-by-layer filling method, eliminating the need for subsequent heat treatment to achieve the desired optical characteristics.
2Reliability
If additional heat treatment steps are performed after production to achieve desired strength and optical properties, then the quality of the dental restoration is improved, but the production time and energy consumption increase
Solution Approach 1:
The forming process and heat treatment process are merged into a single integrated process. The multi-layer powder compact is directly sintered in one heating cycle that simultaneously achieves both formation and heat treatment. This eliminates separate heat treatment steps while maintaining the desired strength and optical properties of the restoration.
Solution Approach 2:
The sintering process parameters (temperature, time, atmosphere) are optimized to achieve both formation and heat treatment in one step. By controlling the sintering parameters appropriately, the restoration attains the required strength and optical properties without requiring additional post-processing heat treatment, thereby reducing production time and energy consumption.
3Illumination intensity
If manual application and burning of coloration layers are required, then the desired aesthetic appearance is achieved, but the ease of manufacture decreases and additional processing steps are needed
Solution Approach 1:
The manual mechanical process of applying and burning coloration layers is replaced by an automated powder forming process. Powders with different compositions (including colorants) are filled into the mold in specific layers using mechanical means, and the coloration is integrated into the structure during sintering. This eliminates manual application and burning steps while achieving the desired aesthetic appearance.
Solution Approach 2:
The restoration is created as a composite structure with multiple powder layers containing different glass compositions and colorants. Each layer contributes specific optical properties, and the composite nature of the material allows desired coloration and translucency to be achieved directly during forming and sintering, without requiring separate manual application and burning operations.
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
Enables the production of dental restorations with desired coloration and translucency without additional heat treatment, allowing for continuous transitions in optical properties, facilitating direct use of the restoration without manual application and burning.
Implementation Method 1
at least one starting lithium silicate glass is melted
Implementation Method 2
the glass melt is quenched
Implementation Method 3
the material of the first layer is mixed with the material of the further layer to form an intermediate layer
Implementation Method 4
the body sintered to produce the blank
Data Source
Figure 1a~1d
Figure 2
Figure 3
AI summary
The invention relates to a method for the production of a restoration from a blank consisting of, or containing, a lithium silicate glass ceramic, wherein at least two layers of ceramic material of different compositions are filled into a mold layer-by-layer and after filling of the layers they are then pressed and sintered, wherein after filling of a first layer this is structured on its surface in such a way that the first layer, viewed across its surface, differs in its height from region to region, and then a layer with a composition that differs from the first layer is filled as a second layer into the mold. After sintering the dental restoration is produced from the blank by mechanical working.