Oversized Bar Interfaces for Denture Registration
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Solution Overview
Problem
The existing CAD/CAM denture manufacturing process faces challenges in precisely and securely fitting a complex-shaped metal bar into the denture, often resulting in small discrepancies in the bar's position and requiring the production of a plaster model, which introduces delays and expenses.
Innovation Solution
A denture support bar system is introduced, featuring a denture material blank with an oversize cutout and a support bar with oversized implant interfaces and tooth abutments. This system allows for precise reference and registration with a milling device, enabling the secure integration of the support bar into the denture material blank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CAD/CAM technology is used to manufacture dentures directly without plaster models, then production time and costs are reduced, but the ability to precisely align and position the bar in the denture cavity is compromised
Solution Approach 1:
The bar is pre-positioned and integrated into the denture material blank before the final denture fabrication process. The oversized implant interfaces and tooth abutments are created in advance on the bar, allowing it to be securely registered with the denture cavity without requiring a plaster model during production
Solution Approach 2:
The oversized implant interfaces and tooth abutments serve as intermediary registration features between the bar and the denture cavity. These enlarged features facilitate precise alignment and positioning by providing robust reference points that can be accurately matched during the CAD/CAM manufacturing process
2Loss of information
If the full shape of the bar is used for reference and registration, then complete bar positioning information is available, but small discrepancies still occur in bar position
Solution Approach 1:
Instead of relying on the entire bar shape for registration, the invention concentrates the registration function in specific localized areas: the implant interfaces and tooth abutments. These localized features are enlarged and optimized specifically for reference and registration purposes, providing more accurate positioning information than the full bar shape alone
3Manufacturing precision
If a plaster model is produced to assist with bar alignment, then bar positioning accuracy is improved, but production delay and expense are introduced
Solution Approach 1:
The invention extracts and eliminates the plaster model step from the manufacturing process. By integrating the bar directly into the denture material blank with pre-created oversized reference features, the system achieves accurate bar alignment without requiring the intermediate plaster model, thereby removing the associated time delay and expense
Data Source
AI summary
An improved denture system is disclosed. An improved denture system has a support bar and a denture material blank. The denture material blank has an oversize cutout to secure the support bar. The support bar has oversized implant interfaces and optional oversized tooth abutments. After securing the support bar in the denture material blank the final shape and dimensions of the implant interfaces and optionally the final shape and dimensions of the tooth abutments will be machined. The denture system will result in an accurate reference and registration between the denture teeth and base and the implant interfaces.