Multi-Chromatic Dental Appliance Layered Manufacturing
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Solution Overview
Problem
Existing digital workflows for dental appliances require both the outer and inner shapes to be known prior to machining, limiting the ability to create layered, multi-chromatic dental appliances with distinct optical properties for a natural appearance.
Innovation Solution
The method involves separating the steps for designing and creating the outer and inner layers of a dental appliance, allowing for the formation of a first article with a desired outer shape followed by the subtraction of an inner portion to form a cavity, which is then filled with a second material of different optical properties to create a multi-chromatic appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If both outer and inner shapes are known prior to machining, then manufacturing precision can be maintained, but the ability to create layered multi-chromatic dental appliances is limited
Solution Approach 1:
The patent segments the dental appliance manufacturing process into distinct phases: first creating the outer shell with desired aesthetic properties, then separately defining and machining the inner cavity. This segmentation allows each layer to be optimized independently for its specific function (aesthetics vs. fit), enabling multi-chromatic layered structures while maintaining precision through separate digital workflow control for each segment
Solution Approach 2:
The patent applies preliminary action by first creating the outer shell with its final aesthetic form before the inner cavity is defined. The outer layer is prepared in advance with precise optical properties and surface characteristics, then the inner cavity is subsequently created within this pre-formed structure, allowing each layer to be optimized for its specific requirements
2Shape
If a monolithic composition is used, then structural uniformity is achieved, but visual appearance becomes monotonous and less natural
Solution Approach 1:
The patent applies local quality by giving different regions of the dental appliance different material properties and compositions. The outer shell has optimized aesthetic properties (translucency, color, surface texture) while the inner core has optimized mechanical properties (strength, fit, structural integrity). This local differentiation creates a natural multi-chromatic appearance while maintaining overall structural stability through appropriate material selection for each region
Solution Approach 2:
The patent uses composite material structures with distinct outer and inner layers. The outer shell material is selected for aesthetic properties including translucency and color matching natural teeth, while the inner core material provides structural support and precise fit. This composite approach creates visual distinction and natural appearance while maintaining structural uniformity and stability through the integrated layered design
3Adaptability or versatility
If outer and inner layers are created separately, then multi-chromatic appearance is achieved, but process complexity increases
Solution Approach 1:
The patent merges the separate workflows for creating outer and inner layers into a unified digital manufacturing process. The outer shell and inner cavity are designed, simulated for fit, and machined in an integrated sequence using coordinated digital models, reducing process complexity despite the multi-layer structure. This unified approach streamlines the creation of multi-chromatic appearances through coordinated digital planning and sequential manufacturing steps
Data Source
Figure 1
AI summary
A method of making a multi-chromatic dental appliance. A first article can be formed of a first material based on a first digital surface representation having a desired outer shape of the dental appliance. A portion of the first article can then be removed to form an outer layer of the dental appliance comprising a cavity dimensioned to accommodate an inner layer. A second article can be formed by filling the cavity of the first article with a second material. The second material can have at least one different optical property than the first material. The second article can be further processed, as desired. For example, a desired inner shape of the dental appliance can be formed in the second article. Such a desired inner shape can be based on a second digital surface representation of a dental object configured to receive the dental appliance.