Monolithic Dental Implants via Additive Manufacturing
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Solution Overview
Problem
Current dental implant manufacturing processes are complex, costly, and wasteful, particularly when creating porous structures for improved osseointegration, as they require multiple machined parts and complex assembly methods.
Innovation Solution
Additive manufacturing methods are used to create monolithic dental implants with integrated porous and non-porous structures, allowing for customized porosity gradients and reduced material waste by forming the entire implant in a single piece, including features like threads and abutment interfaces during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional machining methods are used to create porous structures for dental implants, then osseointegration is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent merges the porous structure creation with the base implant manufacturing into a single additive manufacturing process. The porous coating and implant body are formed simultaneously in one piece, eliminating the need for separate machining operations and assembly steps. This resolves the contradiction by maintaining the osseointegration benefits of porous structures while eliminating the manufacturing complexity of traditional multi-step processes.
Solution Approach 2:
The patent directly creates porous structures through additive manufacturing by controlling the deposition process to form interconnected pore spaces. This allows the implant to achieve osseointegration without requiring complex post-processing or assembly of porous coatings, as the porosity is inherently built into the structure during manufacturing.
2Reliability
If traditional machining methods are used to create porous structures, then osseointegration is improved, but material waste increases
Solution Approach 1:
By combining the porous structure creation with implant manufacturing in a single additive process, the patent eliminates the need to machine away large amounts of material to create porous features. The porous structure is built up layer by layer with minimal material waste, resolving the contradiction between achieving osseointegration and reducing material loss.
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (machining) to additive (deposition), fundamentally altering how material is used. This parameter change allows the creation of porous structures with near-net-shape accuracy, dramatically reducing material waste while maintaining the osseointegration benefits.
3Reliability
If multiple separate parts are assembled to create dental implants with porous sections, then osseointegration is achieved, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple separate components (implant body, porous coating, threads, abutment interface) into a single monolithic structure manufactured in one additive process. This eliminates assembly operations and reduces manufacturing time, resolving the contradiction between achieving osseointegration through porous structures and maintaining high productivity.
Solution Approach 2:
The additive manufacturing process creates a multi-functional monolithic implant that simultaneously provides structural support, osseointegration surfaces, threading for bone engagement, and abutment interface features. This universal approach eliminates the need for multiple specialized parts and assembly steps, improving manufacturing efficiency while maintaining all necessary functions.
4Reliability
If complex assembly methods are used to create dental implants with porous structures, then osseointegration is improved, but device complexity increases
Solution Approach 1:
The patent merges the porous structure and implant body into a single monolithic component manufactured by additive processes. This eliminates complex assembly operations involving multiple parts, fasteners, or joining methods, while preserving the osseointegration benefits of porous surfaces.
Solution Approach 2:
The patent creates porous structures directly as an integral part of the monolithic implant through additive manufacturing. This eliminates the need for separate porous coatings or inserts that would require complex assembly, simplifying the overall device while maintaining osseointegration capabilities.
Data Source
AI summary
A monolithic dental implant formed from an additive manufacturing method can include a non-porous portion and a porous structure. The porous structure can increase osseointegration of the dental implant and increase the secondary stability.