Orthodontic Bracket Mockup Using Virtual Analog Shapes
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Solution Overview
Problem
Current methods for precise positioning of orthodontic brackets in orthodontic treatments are costly and prone to manual assembly errors, and existing solutions do not efficiently facilitate the creation of transfer trays that allow for easy placement and removal of brackets without damaging the tray or the patient's teeth.
Innovation Solution
A method involving the creation of a virtual mockup of a patient's dental arch and orthodontic brackets, where the shapes of the analogs approximate but differ from the brackets, allowing for additive manufacturing of a physical mockup that enables the production of a transfer tray with precise positioning and easy bracket placement, minimizing manual assembly tolerances and the need for external dental labs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual assembly methods are used to position orthodontic brackets, then manufacturing precision can be achieved, but the process is costly and prone to manual assembly errors
Solution Approach 1:
The patent uses virtual analogs that approximate the shape of orthodontic brackets to create a virtual mockup of the dental arch. These virtual analogs are then used to generate a physical mockup through additive manufacturing. The virtual analogs replicate the essential geometric features needed for positioning while simplifying the manufacturing process and eliminating manual assembly errors associated with traditional methods.
Solution Approach 2:
The patent replaces manual mechanical assembly with a digital workflow. Virtual analogs are created using computational geometry, merged with virtual dental arch models, and processed through additive manufacturing. This substitution of manual mechanical operations with digital design and automated manufacturing achieves higher precision while reducing complexity.
2Manufacturing precision
If existing solutions are used for creating transfer trays, then bracket positioning is possible, but the trays are difficult to remove without damaging the patient's teeth
Solution Approach 1:
The patent applies different geometric characteristics to different regions of the transfer tray. The tray includes localized receptacles with specific geometric features that match the virtual analogs, allowing precise bracket positioning. These localized features are designed to facilitate easy removal without damaging teeth, while maintaining overall positioning precision through the coordinated geometry of the receptacles and analogs.
3Manufacturing precision
If physical mockups are made using traditional methods, then bracket positioning can be demonstrated, but the process is time-consuming and requires external dental labs
Solution Approach 1:
The patent performs all preparatory actions digitally before physical manufacturing. Virtual analogs are created, positioned, and merged with virtual dental arch models in advance. The virtual mockup is generated and validated computationally before being sent to additive manufacturing. This preliminary digital preparation eliminates the need for external dental labs and significantly reduces production time while maintaining precision.
Solution Approach 2:
The patent replaces traditional mechanical mockup fabrication with additive manufacturing based on digital models. The virtual mockup data is directly processed by 3D printing or similar additive manufacturing technologies, eliminating intermediate mechanical processing steps and external lab requirements. This substitution dramatically increases productivity while preserving manufacturing precision.
4Manufacturing precision
If customized brackets are designed for each tooth and patient, then clinical accuracy is improved, but the complexity of placement increases
Solution Approach 1:
The patent creates virtual analogs that capture the essential geometric features of customized brackets for each tooth and patient. These virtual analogs are simplified representations that retain the necessary positioning information while being easier to work with in the virtual and physical mockup processes. The analogs are then used to generate physical mockups that demonstrate accurate placement without requiring complex manual assembly procedures.
Data Source
AI summary
A method of making a physical mockup the method comprises the steps of providing a virtual dental arch, a virtual set of orthodontic brackets for the virtual dental arch and a virtual set of analogs. Each analog is associated with a virtual bracket of the virtual set of brackets and the shape of at least one of the analogs differs from the shape of the associated bracket. The method further comprises the steps of providing a virtual mockup in which the virtual dental arch and the set of virtual analogs are merged, and manufacturing the physical mockup based on the virtual mockup. The physical mockup represents a shape composed of the shape the dental arch and the shape of the set of analogs. The invention facilitates bonding of brackets to a patent's teeth.