Additive Manufacturing System with Multi-Resin Vat for Dental Restorations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing systems for dental restorations are limited in achieving high mechanical stability and aesthetic quality, particularly in creating tooth color gradations and translucency, while also requiring sintering steps and being inefficient in automation and cost-effectiveness.
Innovation Solution
An additive manufacturing system with a light permeable base and build carrier that uses multiple resin supplies to layer different light-hardenable resins, allowing for controlled emission of light to harden the resins, enabling the creation of dental restorations with natural tooth color gradations without sintering, and allowing for real-time or parallel treatment during patient care.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single resin is used in stereolithography systems, then the manufacturing process is simple, but the optical aesthetics and color variation capability are limited
Solution Approach 1:
The resin supply system is segmented into multiple independent resin supplies, each capable of holding and dispensing a different light-hardenable resin with distinct optical properties. This segmentation allows the system to switch between resins during the build process, enabling color variations and optical gradients in the manufactured dental restoration while maintaining a modular, manageable system architecture
Solution Approach 2:
Different regions of the resin vat receive different resin types through the multiple resin supplies. The system can selectively apply resins with specific colors, translucencies, or mechanical properties to specific areas of the workpiece being built, achieving local quality variations that mimic natural tooth structure and aesthetics
2Manufacturing precision
If multiple resins are supplied in the same resin vat, then optical aesthetics and color gradation are improved, but resin contamination and mixing issues may worsen
Solution Approach 1:
The resin vat is effectively segmented into multiple zones, each associated with a specific resin supply. Physical barriers or selective dispensing mechanisms prevent different resins from mixing, while still allowing the system to switch between resin types during the layer-by-layer build process, ensuring reliable color and property transitions
Solution Approach 2:
The system introduces intermediary elements such as selective dispensing nozzles, physical partitions, or controlled flow mechanisms that mediate between multiple resin supplies and the build area. These intermediaries ensure that only the intended resin contacts the workpiece at any given time, preventing contamination while enabling smooth transitions between different resin types
3Ease of manufacture
If traditional build-up processes are used, then material can be added to create desired shapes, but sintering steps are required which increase processing time and cost
Solution Approach 1:
The system changes the fundamental parameter of material hardening from thermal (sintering) to photonic (light-induced polymerization). By using light-hardenable resins that cure upon exposure to specific wavelengths, the process eliminates the need for high-temperature sintering steps, dramatically reducing processing time and enabling chairside manufacturing while maintaining the additive build-up capability
4Productivity
If automated build-up processes are implemented, then productivity increases, but system complexity and initial costs increase
Solution Approach 1:
The system integrates multiple functions into a single platform: the light source serves both as the curing mechanism and the pattern projection system; the build carrier provides both support and positioning; the resin supplies are controlled by a unified system that manages both material delivery and build process coordination. This multi-functionality increases productivity while limiting the growth of system complexity
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
The system achieves high optical aesthetics and mechanical stability, enabling rapid production of dental restorations with natural tooth color gradations, enhancing automation, and reducing costs by eliminating the need for sintering and allowing for on-site chairside manufacturing.
Implementation Method 1
a light source which is arranged to emit light through the light permeable base toward a region between the light permeable base and the build carrier
Data Source
AI summary
An additive manufacturing system has a light permeable base, a build carrier for holding a workpiece and a light source which is arranged to emit light through the light permeable base. The light permeable base and the build carrier are positionable relative to each other in a build dimension in which the workpiece is built up. The system further has a resin vat in which the light permeable base forms a wall portion thereof. The system further comprises a plurality of resin supplies for supplying different light hardenable resins in direct contact with each other in said vat. The system facilitates the rapid manufacturing of a dental restoration having a color gradation.