Orthodontic Wire Manufacturing for Treatment and Dentition Maintenance
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Solution Overview
Problem
Conventional orthodontic wire manufacturing methods are inefficient, lack precision, and do not adequately consider the differences between orthodontic processes and dentition maintenance processes, leading to suboptimal wire suitability and increased production costs.
Innovation Solution
A system and method for manufacturing orthodontic wires that include a teeth data obtaining part, simulating part, calculating part, and wire manufacturing part to determine the necessary process (orthodontic or dentition maintenance) based on teeth data, with a correcting part generating a compensation algorithm for the elastic restoring force, especially for dentition maintenance, using an orthodontic wire bending machine with a bending unit, guide zig, and cutting unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual manufacturing methods are used, then worker skill determines quality, but production time and cost increase
Solution Approach 1:
The patent replaces manual mechanical bending operations with an automated robotic bending machine that uses computer-controlled mechanisms. The system substitutes human skill-based manual operations with automated mechanical systems guided by digital models, enabling consistent precision while increasing production efficiency
Solution Approach 2:
The patent implements heating the wire material to specific temperatures before bending to reduce its elastic restoring force. This parameter change (temperature) allows the wire to be bent more easily and held in the desired shape, improving manufacturing precision while reducing the complexity of the bending machine
2Manufacturing precision
If conventional bending machine is used, then rectangular wire can be bended, but bending accuracy is limited due to material elasticity
Solution Approach 1:
The patent applies thermal heating to the wire material to change its physical properties, specifically reducing the elastic restoring force by increasing temperature. This allows the wire to be bent to precise angles and positions without requiring excessively complex bending mechanisms, as the heated material more readily accepts and maintains the desired shape
Solution Approach 2:
The patent performs preliminary heating of the wire before the bending operation. This preliminary action modifies the material properties in advance, making the wire more pliable and easier to bend accurately, thereby reducing the complexity requirements of the bending machine itself
3Ease of manufacture
If single treatment approach is used, then manufacturing is simplified, but patient suitability decreases
Solution Approach 1:
The patent divides the orthodontic treatment into multiple distinct phases (orthodontic process and dentition maintenance process) and manufactures different wire types for each phase. This segmentation allows customization of wire properties for specific treatment stages while maintaining clear manufacturing protocols for each wire type
Solution Approach 2:
The patent applies different material properties and design characteristics to different wire types based on their specific用途. The first wire type has properties optimized for active orthodontic movement, while the second wire type has properties optimized for maintenance, creating local quality variations that enhance patient suitability for different treatment phases
4Productivity
If conventional wire is used for both processes, then production is efficient, but treatment effectiveness decreases
Solution Approach 1:
The patent segments the wire product line into distinct types for different treatment phases. This segmentation enables efficient standardized manufacturing of each wire type while ensuring that the appropriate wire with correct properties is used for each specific orthodontic or maintenance phase, thereby maintaining treatment effectiveness
Solution Approach 2:
The patent modifies material parameters (such as elastic restoring force, diameter, and composition) to create different wire types optimized for specific phases. These parameter changes allow efficient manufacturing through standardized processes for each wire type while ensuring optimal treatment effectiveness for each phase through tailored material properties
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 faster, more precise, and patient-specific orthodontic wire production, enhancing treatment effectiveness by matching wire properties to the specific process needs, reducing production time and costs, and maintaining dentition without distortion.
Implementation Method 1
considering an elastic restoring force of the orthodontic wire
Data Source
Figure 1
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Figure 4
AI summary
In a system of manufacturing an orthodontic wire, a method for manufacturing the orthodontic wire using the system, and an orthodontic wire bending machine for performing the system, the system includes a teeth data obtaining part (10), a simulating part (20), a calculating part (50) and a wire manufacturing part (60). The teeth data obtaining part (10) obtains present teeth data of a patient. The simulating part (20) generates final teeth data. The calculating part (50) compares a predetermined threshold to a compared value between the present teeth data of the patient and the final teeth data. The wire manufacturing part (60) selectively manufactures a wire for an orthodontic process or a wire for a dentition maintenance process based on a compared result of the calculating part (50).