Orthodontic Aligner 3D Printing and UV Curing
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Solution Overview
Problem
The existing methods for forming orthodontic aligners are time-consuming and costly due to the multiple steps required, including the creation of dental casts and subsequent thermoforming, which limits the efficiency and logistical operations in the fabrication process.
Innovation Solution
A method and apparatus that involve three-dimensional printing of an intermediate structure using biocompatible thermoplastic filaments, followed by coating with a translucent photopolymer and UV curing, or thermoforming a pre-cut aligner sheet over a dental cast, to directly form orthodontic aligners without the need for intermediate casts, allowing for variable thickness and reduced manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dental casts are created using stereolithography and post-processing, then accurate tooth models are obtained, but manufacturing time and process complexity increase
Solution Approach 1:
The invention extracts and eliminates the dental cast creation step from the traditional aligner manufacturing process. By using 3D printed intermediate structures directly as forming molds for the aligners, the patent removes the time-consuming stereolithography and post-processing steps while maintaining the necessary precision for tooth model accuracy.
Solution Approach 2:
The manufacturing process is segmented into distinct functional components: 3D printing of intermediate structures with specific geometric features that directly define the aligner shape, eliminating the need for separate cast creation and post-processing steps. This segmentation allows parallel processing and reduces sequential dependencies.
2Manufacturing precision
If multiple intermediate steps including dental cast creation and thermoforming are used, then aligners are formed with proper shape, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges the functions of dental cast creation and aligner forming into a single integrated process. The 3D printed intermediate structures serve dual purposes as both the tooth model representation and the forming mold, combining multiple functions into one component and eliminating the need for separate dental cast creation and subsequent thermoforming operations.
Solution Approach 2:
The intermediate structures are designed with universal geometric features that directly define the aligner shape and function. These structures serve multiple functions: representing the tooth model, defining the aligner geometry, and acting as the forming mold itself, thereby reducing the number of specialized components and steps required.
3Manufacturing precision
If traditional thermoforming process is used, then aligners are formed from thermoplastic sheets, but manufacturing time and logistical operations increase
Solution Approach 1:
The invention replaces the traditional mechanical thermoforming process with a direct 3D printing approach. Instead of heating and mechanically forming thermoplastic sheets over dental casts, the aligners are formed through additive manufacturing of intermediate structures that directly define the final aligner geometry, eliminating the thermal and mechanical forming steps.
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 significantly reduces manufacturing time and cost by eliminating the need for dental casts and enables custom variable thickness aligners for improved clinical efficacy and comfort, while also simplifying the logistical operations.
Implementation Method 1
three-dimensionally printing an intermediate structure comprising fused filaments from a biocompatible thermoplastic according to the aligner digital model via fused deposition modelling
Implementation Method 2
irradiating the coating with ultraviolet light to cure the coating on the intermediate structure, thereby forming the orthodontic aligner
Data Source
AI summary
A method of forming an orthodontic aligner from an aligner digital model, the method comprising the steps of: three-dimensionally printing an intermediate structure comprising fused filaments from a biocompatible thermoplastic according to the aligner digital model via fused deposition modelling; coating the intermediate structure with a biocompatible translucent photopolymer; and irradiating the coating with ultraviolet light to cure the coating on the intermediate structure, thereby forming the orthodontic aligner.