Corrective Orthodontic Staging Using Surface-Matched Teeth Models

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Solution Overview

Problem

Conventional orthodontic methods fail to provide an exact model of a patient's teeth for accurate tracking of tooth movement, leading to deviations from the prescribed treatment course and the need for re-starting the treatment process due to improper fitting of appliances.

Innovation Solution

A system and method that uses a Previously Segmented Teeth Model to generate corrective stages, allowing for the adjustment of off-track teeth to a pre-existing prescribed tooth arrangement, thereby enabling the reuse of existing appliances and avoiding the need for a new series of appliances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional methods use standard 3D digital model template with standard teeth to track tooth movement, then the process is simple and quick, but the model is not exact and cannot accurately track tooth movement or fabricate adjustment appliances

Engineering Contradiction:
Improveaccuracy of tooth position trackingVSAvoidcomplexity of teeth modeling process
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent creates a precise digital copy of the patient's actual teeth geometry by scanning their physical teeth with an intraoral scanner. This digital replica exactly reproduces the unique shape, size, and position of each patient tooth, replacing the generic standard teeth model. This copy enables accurate tracking of tooth movement throughout treatment and precise fabrication of adjustment appliances that fit the patient's specific anatomy.

Inventive Principle:
Principle #26Copying

2Reliability

If a patient strays from the prescribed course of treatment, then the treatment plan needs to be restarted with new appliances, but this wastes time and resources

Engineering Contradiction:
Improveadherence to treatment planVSAvoidtime lost due to treatment re-start
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent implements continuous feedback by comparing the patient's actual tooth position (captured through intraoral scanning) against the prescribed treatment plan at each stage. This feedback mechanism detects deviations early, allowing the orthodontist to identify when a patient has strayed from the planned course. The system then enables correction by generating modified treatment stages that account for the actual tooth positions, preventing complete treatment re-start and reducing time loss.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The treatment plan becomes dynamic rather than static. Instead of following a rigid predetermined sequence of appliances, the system allows real-time modification of treatment stages based on actual tooth movement progress. When deviations are detected, the system dynamically generates corrective treatment stages that adapt the original plan to the patient's current state, enabling flexible continuation rather than complete re-start.

Inventive Principle:
Principle #15Dynamics

3Productivity

If standard teeth in a 3D model are moved to reflect general tooth position, then the model can be created quickly, but the size and shape variations from actual teeth prevent accurate tracking

Engineering Contradiction:
Improvespeed of model creationVSAvoidaccuracy of tooth geometry representation
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces the manual mechanical process of moving standard teeth in a 3D model with an automated digital scanning and modeling system. An intraoral scanner captures the patient's actual teeth geometry, and software automatically generates a precise digital model. This substitution eliminates the need to manually manipulate standard teeth to match patient anatomy, achieving both high speed (automation) and high precision (actual geometry capture).

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12558192B2System and method for determining a corrective stage in orthodontic treatment
Publication Date: 2026.02.24 ALIGN TECHNOLOGY INC
  • US12558192B2 patent drawing
  • US12558192B2 patent drawing
  • US12558192B2 patent drawing

AI summary

Methods and systems for determining a corrective stage in orthodontic treatment. Methods may include presenting a menu for a user to enter a pre-determined tolerance or a maximum number of iterations for performing a surface matching algorithm. Methods may include matching one or more teeth of a previously segmented teeth model to one or more corresponding teeth of a current teeth image. The matching may include executing the surface matching algorithm. The methods may include iteratively finding closes sample points, determining whether distances between closest sample points exceed a predetermined tolerance, and adjusting the distances. A current teeth model may be generated based on the adjusted previously segmented teeth model. A current teeth model using the corrective stage may be generated.