Orthodontic Aligner Layer-by-Layer Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional orthodontic aligners face challenges such as high manufacturing costs and time, limited aperture shapes, difficulty in attachment installation and removal, discomfort due to inaccurate trimming, and potential TMJ injury from unbalanced occlusion forces, which are not adequately addressed by existing methods.
Innovation Solution
A method for direct fabrication of orthodontic devices using layer-by-layer printing of polymeric materials, allowing for a wider range of features and functions, including variable thickness and reinforced occlusal surfaces, and enabling the creation of day and night appliances with different thicknesses and materials, which can be manufactured remotely and evaluated for stress using light refraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding processes are used to fabricate aligners, then manufacturing precision can be achieved, but manufacturing time and costs increase significantly
Solution Approach 1:
The method performs preliminary digital planning and design of the entire aligner series before manufacturing begins. Treatment outcomes are simulated and tooth movement paths are predetermined in silico, allowing the actual fabrication process to proceed efficiently without repeated adjustments or remakes, thus reducing overall manufacturing time while maintaining precision
Solution Approach 2:
The invention replaces conventional mechanical molding processes with a digital workflow that uses computer-aided design and computer-aided manufacturing (CAD/CAM). Digital models are transformed into manufacturing data through software algorithms, eliminating the need for physical master models and manual molding setup, thereby significantly reducing manufacturing time while preserving or improving precision
2Adaptability or versatility
If conventional aligners are used, then basic tooth movement is achieved, but aperture shapes are limited and attachment installation is difficult
Solution Approach 1:
The invention utilizes variable thickness design where the aligner material thickness is adjusted at different locations based on specific treatment requirements. Thinner regions provide flexibility for tooth movement while thicker regions provide strength for attachment retention. This parameter variation enables diverse aperture shapes and optimized attachment installation without compromising overall aligner performance
Solution Approach 2:
The aligner is designed with non-uniform properties where different regions have different thicknesses and material characteristics tailored to local requirements. Areas requiring attachment installation have optimized thickness and geometry for easy placement, while other areas maintain properties suitable for tooth movement, thereby achieving both versatility and ease of operation
3Reliability
If conventional aligners are used, then treatment is effective, but unbalanced occlusion forces may cause TMJ injury
Solution Approach 1:
The method incorporates digital simulation and analysis that provides feedback on the predicted effects of each aligner on tooth movement and occlusion. The software evaluates force distribution patterns and identifies potential imbalances before manufacturing, allowing adjustments to be made to the treatment plan to prevent TMJ injury while maintaining treatment effectiveness
4Productivity
If conventional aligners are used, then tooth movement is achieved, but manufacturing costs are high
Solution Approach 1:
The aligners are designed with variable thickness where material is provided only where needed for specific functions such as attachment retention or controlled tooth movement. This partial action approach uses material efficiently, reducing waste and manufacturing costs while maintaining the productivity needed for effective treatment
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 reduces manufacturing costs and time, improves appliance functionality, enhances comfort by avoiding inaccurate trimming, and minimizes TMJ injury by providing controlled force distribution, while allowing for more precise and efficient tooth movement and occlusion management.
Implementation Method 1
A method for direct fabrication of orthodontic devices using layer-by-layer printing of polymeric materials
Implementation Method 2
evaluated for stress using light refraction
Data Source
AI summary
A method for fabrication of an orthodontic device having tooth-fitting cavities, such as an aligner, using layer-by-layer printing of a single or multiple polymeric materials. The cavities of the appliance or an appliance mold are defined by the boundaries of the multiple layers, encapsulating up to fourteen teeth of a patient, and shaped to apply a load to at least one tooth that is sufficient to cause movement of the tooth, and remodeling of the adjacent bone. In the case where the cavities form an appliance mold, the mold is used to form a positive model and an appliance is formed thereon. A series of such appliances may be used to treat malocclusion of teeth, each appliance used in series to incrementally move one or more teeth from initial positions toward a desired final position. The appliance may be fabricated with a variety of disclosed materials, and may include auxiliary features for interaction with other orthodontic elements.