Multi-Material Orthodontic Aligner Geometry for Precise Force Control
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Solution Overview
Problem
Prior orthodontic appliances with homogeneous material properties lack control over force application to teeth, are sensitive to manufacturing tolerances, and have inaccuracies in attachment placement, leading to less than ideal tooth movement and increased costs.
Innovation Solution
The development of orthodontic appliances with heterogeneous properties, featuring a stiff outer shell and a compliant inner structure, which allows for customized force and torque application to different subsets of teeth, and improved manufacturing methods for precise appliance design and fabrication, including 3D scanning and direct fabrication techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If homogeneous material properties are used in orthodontic appliances, then manufacturing is simpler and cost is reduced, but control over force application to different teeth is insufficient
Solution Approach 1:
The patent applies local quality by varying the material properties (stiffness, elasticity) at different locations within the orthodontic appliance. Different regions of the appliance are designed with distinct material characteristics to provide customized force and torque application to specific teeth, thereby achieving precise force control while maintaining a unified appliance structure.
Solution Approach 2:
The patent utilizes composite materials by combining multiple materials with different mechanical properties within a single appliance. This allows the appliance to exhibit heterogeneous properties, where certain regions are stiffer for structural support while other regions are more compliant for force application, resolving the contradiction between manufacturing simplicity and force control capability.
2Strength
If stiff orthodontic appliances are used, then structural integrity is improved, but manufacturing tolerances must be tighter and accuracy is reduced
Solution Approach 1:
The patent applies parameter changes by varying the material properties (stiffness, elasticity) at different locations within the orthodontic appliance. Different regions are designed with distinct material characteristics to provide customized force and torque application to specific teeth, thereby achieving precise force control while maintaining a unified appliance structure.
Solution Approach 2:
The patent utilizes composite materials by combining multiple materials with different mechanical properties within a single appliance. This allows the appliance to exhibit heterogeneous properties, where certain regions are stiffer for structural support while other regions are more compliant for force application, resolving the contradiction between manufacturing simplicity and force control capability.
3Adaptability or versatility
If heterogeneous material properties are used in orthodontic appliances, then control over force application to different teeth is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the material properties (stiffness, elasticity) at different locations within the orthodontic appliance. Different regions of the appliance are designed with distinct material characteristics to provide customized force and torque application to specific teeth, thereby achieving precise force control while maintaining a unified appliance structure.
Solution Approach 2:
The patent utilizes composite materials by combining multiple materials with different mechanical properties within a single appliance. This allows the appliance to exhibit heterogeneous properties, where certain regions are stiffer for structural support while other regions are more compliant for force application, resolving the contradiction between manufacturing simplicity and force control capability.
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
This approach provides more accurate and reliable tooth movement with consistent force application, reduced sensitivity to manufacturing tolerances, and cost-effective production, enhancing the predictability and effectiveness of orthodontic treatments.
Implementation Method 1
an inner structure having a stiffness different than a stiffness of the outer shell. The inner structure may be positioned on an inner surface of the outer shell in order to distribute the one or more of a force or a torque to at least one received tooth
Data Source
AI summary
Methods for designing orthodontic appliances for repositioning a patient's teeth are provided. In some embodiments, a method includes determining a movement path to move one or more teeth from an initial arrangement to a target arrangement, determining a force system to produce movement of the one or more teeth along the movement path, and determining an appliance geometry for an orthodontic appliance configured to produce the force system. The orthodontic appliance can include an outer shell comprising a plurality of teeth-receiving cavities and an inner structure positioned on an inner surface of the outer shell. The inner structure can have an elastic modulus different than an elastic modulus of the outer shell. The method can also include generating instructions for directly fabricating the orthodontic appliance using a layer-by-layer additive manufacturing technique.