Orthodontic Bracket Laser Manufacturing Compensation
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Solution Overview
Problem
Existing orthodontic appliances face challenges in achieving precise dimensions and configurations due to manufacturing inaccuracies, particularly with laser-based systems, leading to imperfect fits between orthodontic brackets and archwires, which can result in unpredictable orthodontic effects, prolonged treatment duration, and increased pain and expense.
Innovation Solution
A method and system using a computer-connected laser-based system to determine and apply a compensation factor for manufacturing orthodontic brackets, ensuring precise groove dimensions and rear surface conformity to a patient's tooth contour, by aligning a three-dimensional digital model and adjusting the amount of material used based on deviations from desired angles and positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If laser-based additive manufacturing is used to make orthodontic brackets, then manufacturing flexibility and customization are improved, but manufacturing precision and dimensional accuracy deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-calculating compensation factors and incorporating them into the digital model before manufacturing. The system determines the deviation of the groove base position and adjusts the digital model in advance to compensate for expected laser beam angle deviations, ensuring the final manufactured bracket achieves the desired precision despite laser-based manufacturing limitations.
Solution Approach 2:
The patent changes parameters by adjusting the digital model parameters (groove base position, angles) based on calculated compensation factors. The system modifies the digital representation of the bracket to account for laser manufacturing inaccuracies, transforming the model parameters so that when manufactured, the physical bracket achieves the target dimensions and fit.
2Ease of manufacture
If traditional casting methods are used to make brackets, then manufacturing simplicity is maintained, but fit precision between bracket groove and archwire deteriorates due to oxide film and shrinkage
Solution Approach 1:
The patent replaces the traditional mechanical casting process with laser-based additive manufacturing combined with digital compensation. This substitution eliminates the harmful effects of oxide film formation and linear shrinkage inherent in casting, while the digital compensation system addresses the laser manufacturing precision issues, achieving both simplicity and precision.
Solution Approach 2:
The patent converts the inherent inaccuracy of laser beam angle deviations into a benefit by calculating compensation factors that deliberately adjust the digital model. What would normally be a source of error (laser angle deviation) becomes a controlled parameter that, when compensated, actually improves the final fit precision beyond what traditional casting can achieve.
3Manufacturing precision
If compensation factors are calculated and applied to the digital model, then manufacturing precision is improved, but device complexity and processing time increase
Solution Approach 1:
The patent applies self-service by implementing an automated system that calculates compensation factors and adjusts the digital model without manual intervention. The processor automatically determines groove base position deviations, calculates appropriate compensation factors, and modifies the digital model, eliminating the need for complex manual measurements and adjustments while maintaining high precision.
Solution Approach 2:
The patent implements feedback by using the calculated groove base position deviation as input to determine the compensation factor, which then feeds back into the digital model. This closed-loop approach ensures that the compensation is precisely tailored to the specific bracket design and manufacturing parameters, achieving high accuracy without requiring overly complex manual procedures.
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 enables the production of orthodontic appliances with precise dimensions, reducing manufacturing tolerances and surface irregularities, thereby improving the fit between brackets and archwires, enhancing treatment efficiency and reducing treatment duration and complications.
Implementation Method 1
laser-based system
Implementation Method 2
laser-based system
Data Source
AI summary
A method for making an orthodontic appliance comprising: receiving, by a processor of a computer system, a three-dimensional digital model of an orthodontic appliance; determining, by the processor, a compensation factor to be applied when manufacturing the orthodontic appliance using the laser-based system, the determining the compensation factor including: aligning the three-dimensional digital model of the orthodontic appliance in a three-dimensional space with a predetermined position; determining a deviation of a position of a model groove base from a desired position of the model groove base, the compensation factor being based on the deviation and relating to an amount of material to be used during the manufacturing of the orthodontic appliance; causing the laser-based system to apply the compensation factor for manufacturing the orthodontic appliance.