Orthodontic Aligner Fabrication via Local Thermoforming
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Solution Overview
Problem
Current methods for fabricating orthodontic aligners require labor-intensive manual trimming of excess material and lack efficient access to original patterns for replacement or identical sets, leading to increased costs and delays in replacing lost aligners.
Innovation Solution
A method where successive patterns representing incremental stages of an orthodontic treatment plan are sent to the dentist, allowing for thermoforming aligners using a vacuum machine and trimming excess material locally, with the option to retain patterns for replacement and reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If all aligners and patterns are manufactured and shipped to the dentist in advance, then the dentist can access replacement patterns quickly, but the initial manufacturing process becomes more complex and costly
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: (1) centralized digital model creation and pattern fabrication at the manufacturer's facility, and (2) local aligner thermoforming and trimming at the dentist's office. This segmentation allows the complex digital modeling work to be done once centrally, while the simpler physical fabrication is distributed locally, resolving the contradiction between quick replacement access and manufacturing complexity.
Solution Approach 2:
All digital models and treatment patterns are created in advance and shipped to the dentist's office before treatment begins. This preliminary action ensures that replacement patterns are immediately available if an aligner is lost, eliminating delays. The complex digital modeling is performed beforehand, so the dentist only needs to perform the simpler thermoforming process locally.
2Ease of manufacture
If aligners are thermoformed and trimmed locally at the dentist's office, then labor costs are reduced, but the dentist requires additional equipment and training
Solution Approach 1:
The system enables the dentist's office to perform aligner fabrication independently using the shipped patterns. The dentist thermforms aligners from plastic sheets over the received patterns and trims excess material locally. This self-service capability eliminates the need to outsource aligner fabrication, reducing labor costs and providing flexibility, while the equipment required (vacuum former and trimmer) represents a reasonable investment for the capability gained.
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 labor costs by allowing fabrication and trimming of aligners in the dentist's office, enabling quicker replacement of lost aligners and reducing manufacturing delays by providing all necessary patterns in a single shipment.
Implementation Method 1
inserted into a vacuum forming machine and sucked down over the positive pattern
Implementation Method 2
The polymeric sheet is heated so that it is more resilient or pliable
Data Source
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AI summary
The present invention is directed to a method of fabricating a successive set of patterns representing incremental stages of an orthodontic treatment plan, and then sending all or a portion of the successive patterns at the same time to the dentist. The dentist is provided with a vacuum machine for thermoforming a set of aligners as negative impressions of the positive teeth patterns. A polymeric sheet is inserted into a vacuum forming machine and sucked down over the positive pattern, forming a polymeric shell with cavities shaped to receive the teeth and resiliently bias or reposition at least some of the teeth into alignment with the aligner cavities. When the aligner is formed and while still on the stereolithographic plastic pattern, excess portions of the aligner polymeric material are trimmed using manual tools and/or a laser cutting machine.