Orthodontic Bracket Customization via Liquid Embedding
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Solution Overview
Problem
Current manufacturing methods for orthodontic brackets struggle to balance precision and durability with cost-effectiveness, as off-the-shelf brackets are not tailored to individual clinical situations, while precise customization methods are not compatible with mass production at commercially viable costs.
Innovation Solution
A method involving a precursor orthodontic bracket with a predetermined alignment structure and bracket slot geometry, which is modified using a machine to embed partially in a liquid that solidifies, allowing for precise shaping and customization while minimizing manufacturing costs, using techniques like grinding, milling, or selective laser melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If customized orthodontic brackets are manufactured with high precision methods, then manufacturing precision and quality are improved, but manufacturing costs increase and mass production becomes incompatible
Solution Approach 1:
The bracket manufacturing process is divided into two distinct stages: first, mass production of bracket precursors with standardized alignment structures using cost-effective methods; second, precise customization of bracket slots using high-precision machining only where needed. This segmentation allows different manufacturing approaches to be applied to different parts of the product, resolving the contradiction between precision and cost.
Solution Approach 2:
Alignment structures are pre-formed on bracket precursors during mass production before the precise bracket slot customization step. This preliminary action establishes a standardized reference framework that enables subsequent high-precision machining to be performed efficiently and consistently across multiple brackets, making mass production of customized brackets economically viable.
2Ease of manufacture
If off-the-shelf brackets are used, then manufacturing costs are reduced, but adaptability to individual clinical situations deteriorates
Solution Approach 1:
The bracket is segmented into a standardized precursor portion (produced in mass for cost efficiency) and a customized slot portion (adapted to individual clinical needs). This allows the product to simultaneously achieve low manufacturing costs through mass production while maintaining adaptability through personalized customization of the bracket slot geometry.
Solution Approach 2:
Customization is applied locally only to the bracket slot area where clinical adaptability is needed, while the rest of the bracket maintains standardized mass-produced characteristics. This localized customization approach preserves cost advantages of mass production while providing necessary adaptability for individual patient requirements.
3Adaptability or versatility
If fully customized brackets are produced for each patient, then adaptability to individual teeth is improved, but productivity and mass production capability deteriorate
Solution Approach 1:
The manufacturing process is segmented so that standardized precursors are produced in mass using high-productivity methods, then multiple precursors are processed together in parallel during the customization stage. This enables semi-customized brackets to be produced efficiently with improved productivity compared to fully individualized manufacturing.
Solution Approach 2:
Multiple bracket precursors are combined and processed together in the same machining setup, allowing simultaneous customization of multiple brackets. This merging of processing operations maintains productivity by handling multiple items in parallel while still achieving individual customization for each patient's teeth.
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
Enables the serial production of orthodontic brackets with precise and durable fits, adapted to individual clinical needs, while reducing manufacturing costs by allowing for both standardized and customized production.
Implementation Method 1
causing the liquid to solidify and thereby retaining the orthodontic bracket precursor in position
Data Source
AI summary
A method of preparing an orthodontic bracket. Such an orthodontic bracket has a bracket bonding pad and a bracket body with a bracket slot. The method has steps of providing a precursor of an orthodontic bracket into a machine for modifying the shape of the orthodontic bracket precursor. The orthodontic bracket precursor has an alignment structure of a pre-determined geometry. Further the alignment structure and the bracket slot are spatially arranged relative to each other at a pre-determined distance and orientation. The method further has the steps of aligning the orthodontic bracket precursor based on the alignment structure and embedding the orthodontic bracket precursor at least partially in a liquid. The liquid is cause to solidify and thereby the orthodontic bracket precursor is retained in position. The so retained orthodontic bracket precursor is changed in shape. The invention helps finishing pre-finished individually shaped orthodontic bracket precursors in a relatively accurate and controlled manner.