Monolithic Ceramic Dental Support Structure for Implant Stability
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Solution Overview
Problem
The manufacturing of implant-supported dental restorations is complex and often imprecise, particularly in attaching dentures to metal support bars, which can lead to difficulties in registration and stability, and traditional dentures are prone to breakage due to acrylic materials.
Innovation Solution
A monolithic support structure made from a single piece of ceramic material with integrated teeth projections and apertures for attachment to implants, combined with a formable material for artificial teeth and gingiva, designed using patient-specific digital data and manufactured through advanced techniques like CNC milling or 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal support bar is used to connect denture to implants, then the device is stabilized and strengthened to avoid breakage, but fitting the denture onto the bar becomes difficult and imprecise
Solution Approach 1:
The patent combines the support bar and denture into a single monolithic component made of ceramic material. The support structures, teeth, and gingival elements are integrated into one piece rather than being separate components that need assembly. This eliminates the fitting and registration problems between separate parts while maintaining the strength and stability functions.
Solution Approach 2:
The patent uses ceramic material for the monolithic support structure instead of traditional metal bars. The ceramic material provides both the necessary strength and stability while allowing for precise manufacturing through advanced ceramic fabrication techniques, thereby resolving the contradiction between strength and manufacturing precision.
2Ease of manufacture
If a metal bar with separate denture components is used, then the device can be assembled, but it is difficult to preserve the registration of the bar and try-in denture during removal and transportation
Solution Approach 1:
By merging the support bar and denture into a single monolithic component, the patent eliminates the need for assembly and disassembly operations. The registration is inherently preserved because there are no separate parts that could shift or lose alignment during removal and transportation between dentist and laboratory.
3Ease of manufacture
If traditional acrylic denture materials are used, then the denture can be formed easily, but the denture is prone to breakage
Solution Approach 1:
The patent replaces traditional acrylic denture materials with ceramic material for the monolithic support structure. Ceramic provides superior strength and durability while avoiding the breakage problems associated with acrylic. The ceramic material can still be formed into complex shapes including teeth and gingival structures through advanced manufacturing techniques.
4Adaptability or versatility
If a complex series of design steps and multiple patient-dentist visits are required, then the dental restoration can be customized, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The monolithic design allows all customization elements to be integrated into a single manufacturing process. Patient-specific digital data can be used to create a customized monolithic support structure in one go, eliminating the need for multiple design steps, prototypes, and assembly operations that characterize traditional approaches.
Data Source
AI summary
A dental device is described that comprises a monolithic support structure for use in implant-supported dental restoration applications for partially or fully edentulous patients. The monolithic support structure comprises a unitary support body with one or more teeth projections projecting from the support body, and at least one support region providing a framework for integrating discrete artificial teeth adjacent the teeth projections. An implant-supported dental device is also provided that comprises the monolithic support structure, one or more artificial teeth, and a gingival region comprised of a formable material that secures artificial teeth within the framework of the monolithic support structure.