Removable Partial Denture 3D Printing Assembly
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Solution Overview
Problem
The traditional manufacturing process of removable partial dentures is complex, prone to errors due to the use of stone models and heat-activated polymethyl methacrylate, requiring multiple appointments and lengthy workflows, which can lead to inaccuracies and inefficiencies.
Innovation Solution
A method utilizing 3D digital image data to create a removable partial denture directly through 3D printing, eliminating the need for stone models and wax patterns, with a frame and segments designed for slidability and assembly using I-beam structures and resin fasteners, allowing for direct fabrication of cobalt chrome alloy frameworks and tooth segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stone models and heat-activated polymethyl methacrylate are used, then the denture can be manufactured using conventional methods, but the process becomes complex, time-consuming, and prone to errors
Solution Approach 1:
The patent removes stone models and heat-activated polymethyl methacrylate from the manufacturing process, extracting the problematic elements that cause complexity and errors. The frame and segments are fabricated directly using 3D printing technology, eliminating the need for traditional stone model fabrication, surveying, and heat-curing processes that introduce warping and inaccuracies.
Solution Approach 2:
The patent changes the manufacturing parameters from conventional methods to additive manufacturing. The frame is printed using cobalt chrome alloy or similar materials through 3D printing, and segments are fabricated using resin or other materials, fundamentally changing how the denture components are created and eliminating the limitations of traditional heat-cured acrylic processes.
2Ease of operation
If traditional multi-appointment workflow is used, then comprehensive adjustments can be made, but the treatment time and number of visits increase
Solution Approach 1:
The patent performs preliminary digital planning and fabrication of the denture before the patient's final appointment. All components are designed digitally, fabricated in advance using 3D printing, and ready for delivery in a single appointment, eliminating the need for multiple visits for adjustments and remakes that characterize traditional workflows.
Solution Approach 2:
The patent replaces the mechanical traditional workflow with digital workflows. Intraoral scans replace physical impressions, digital design replaces stone model surveying, and 3D printing replaces manual fabrication techniques. This substitution streamlines the process and enables same-day or nearsame-day delivery.
3Manufacturing precision
If stone models are used for fabrication, then traditional manufacturing can proceed, but errors are introduced through duplication and expansion/contraction
Solution Approach 1:
The patent uses digital copying through intraoral scanning instead of physical stone model duplication. The digital scan creates an accurate virtual replica of the patient's oral structures, which is then used for design and fabrication. This eliminates the expansion and contraction errors that occur when physical stone models are created, shipped, and duplicated multiple times during the traditional process.
4Shape
If heat-activated polymethyl methacrylate is used, then the denture base can be formed, but warping occurs during heat processing
Solution Approach 1:
The patent changes the material and processing parameters by using 3D printing to fabricate the frame and segments without heat-activated polymethyl methacrylate. The additive manufacturing process allows precise control of dimensional parameters throughout fabrication, eliminating the thermal warping that occurs during heat-curing of traditional acrylic denture bases.
Data Source
AI summary
A removable partial denture comprises a frame sized and shaped to conform to a mouth inner surface, the frame including a projecting mounting structure; and a segment having a slot for slidably receiving the projecting mounting structure when the segment is assembled to the frame. A method of fabricating a removable partial denture comprises: acquiring 3D digital image data of a patient's mouth and dentition; creating a 3D digital model of a removable partial denture; fabricating a frame shaped to conform to an inner surface of the mouth from the 3D digital model, the frame including a mounting structure; fabricating a segment from the 3D digital model, the segment having a slot for slidably receiving the mounting structure; and inserting the mounting structure of the frame into the slot of the segment to assemble the segment to the frame. The segment can be a tooth segment or a base segment.