Resilient Orthodontic Aligners via Polycarbonate Diol Resin
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Solution Overview
Problem
Existing printable/polymerizable resins used in 3D printing are too brittle for resilient oral appliances like aligners, prone to breaking in the mouth, which can lead to material fragments abrading or puncturing tissue or being swallowed, disrupting treatment and potentially causing serious health consequences.
Innovation Solution
A polymerizable composition comprising 30-65 parts by weight of monofunctional (meth)acrylate monomer(s) with a cured homopolymer glass transition temperature (Tg) of 30°C or greater, and at least one urethane (meth)acrylate with polymerized units of an aliphatic polycarbonate diol, optimized for use in vat polymerization 3D printing to create resilient orthodontic articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing printable/polymerizable resins are used in 3D printing, then the articles can be manufactured, but the articles are too brittle and prone to breaking
Solution Approach 1:
The patent modifies the chemical composition parameters of the resin by incorporating specific monofunctional (meth)acrylate monomers with Tg of 30°C or greater and urethane (meth)acrylates with aliphatic polycarbonate diol units. This changes the material properties to achieve both manufacturability and breakage resistance required for orthodontic appliances
Solution Approach 2:
The patent creates a composite resin system combining multiple components: monofunctional (meth)acrylate monomers, urethane (meth)acrylates containing aliphatic polycarbonate diol polymerized units, and other compatible monomers. This composite approach achieves the desired balance of brittleness and reliability that single materials cannot provide
2Reliability
If resilient orthodontic articles are created, then breakage is reduced, but the composition must be precisely tailored for 3D printing compatibility
Solution Approach 1:
The patent establishes specific parameter ranges for the resin composition: 30-65 parts by weight of monofunctional (meth)acrylate monomer with Tg ≥30°C, and specific amounts of urethane (meth)acrylate with aliphatic polycarbonate diol. These defined parameters simplify manufacturing by providing clear formulation guidelines while achieving the required reliability
Solution Approach 2:
The patent assigns different functional roles to specific components: monofunctional (meth)acrylate monomers provide structural integrity with appropriate Tg, while urethane (meth)acrylates with aliphatic polycarbonate diol provide flexibility and toughness. This functional differentiation enables precise control over material properties for 3D printing applications
3Strength
If the resin composition is optimized for vat polymerization 3D printing, then articles with proper mechanical properties are produced, but viscosity must be carefully controlled
Solution Approach 1:
The patent selects monomers and oligomers with appropriate molecular weights and functional groups that provide the necessary mechanical properties while maintaining viscosity within the 50-500 cP range required for vat polymerization 3D printing processes
Solution Approach 2:
The patent ensures the resin composition is homogeneous and free from fillers, pigments, or other additives that could affect viscosity or curing uniformity. This homogeneity enables consistent flow characteristics and reliable 3D printing performance
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
The resulting orthodontic articles exhibit low brittleness, good resistance to water, and high toughness, minimizing the risk of breakage and ensuring safe and uninterrupted treatment.
Implementation Method 1
The use of stereolithography and inkjet printing to produce three-dimensional articles has been known for a relatively long time, and these processes are generally known as methods of so called 3D printing (or additive manufacturing). In vat polymerization techniques (of which stereolithography is one type), the desired 3D article is built up from a liquid, curable composition with the aid of a recurring, alternating sequence of two steps: in the first step, a layer of the liquid, curable composition, one boundary of which is the surface of the composition, is cured with the aid of appropriate radiation
Data Source
AI summary
The present disclosure provides an orthodontic article including the reaction product of the polymerizable composition. Further, the present disclosure provides polymerizable compositions and methods of making an orthodontic article. The method includes obtaining a polymerizable composition and selectively curing the polymerizable composition to form an orthodontic article. Further, methods are provided, including receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying an orthodontic article; and generating, with the manufacturing device by an additive manufacturing process, the orthodontic article based on the digital object. A system is also provided, including a display that displays a 3D model of an orthodontic article; and one or more processors that, in response to the 3D model selected by a user, cause a 3D printer to create a physical object of an orthodontic article.