Reusable Die Dental Model for Thermoforming

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Solution Overview

Problem

The production of polymer dental aligners results in significant waste due to the need for a different custom model for each successive aligner, leading to excessive discarding of polymer material, which poses environmental concerns.

Innovation Solution

A method involving a custom dental model with a receptacle for a reusable die, where the die is removably received and configured to stabilize the model for thermoforming, allowing for the reuse of the die and reduction in the volume of polymer used, utilizing additive manufacturing techniques like stereolithography to create the model and die assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a custom dental model is produced for each successive aligner, then the aligner can be customized to fit the patient's specific tooth position, but a large number of models are discarded leading to significant polymer waste

Engineering Contradiction:

Improvecustomization of alignerVSAvoidpolymer waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The dental model is segmented into two functional parts: a reusable base model containing the receptacle and die, and a disposable patient-specific overlay. This segmentation allows the majority of the model structure to be reused across multiple patients while only the patient-specific portion needs to be customized and discarded, significantly reducing polymer waste while maintaining customization capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base model with receptacle and die is designed as a universal component that can accommodate multiple different patient-specific overlays. This multi-functional design allows a single base model to serve numerous patients, reducing the need to produce entirely new models for each patient and thereby reducing polymer consumption and waste.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If a custom dental model is produced for each aligner, then the model can accurately represent the patient's teeth, but the volume of polymer material required increases significantly

Engineering Contradiction:

Improveaccuracy of tooth representationVSAvoidpolymer volume

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The model is divided into a reusable base structure and a patient-specific overlay. The base structure contains the receptacle and die and is manufactured once, while only the thinner patient-specific overlay needs to be additively manufactured for each patient. This segmentation dramatically reduces the total polymer volume required while maintaining the accuracy of tooth representation through the customized overlay layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of manufacturing entirely new custom models for each patient, the invention uses a reusable base model that is copied and combined with patient-specific data layers. The patient-specific overlay is essentially a thin copied representation of the patient's teeth that fits over the universal base, reducing polymer consumption while preserving manufacturing precision.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If additive manufacturing is used to create custom models for each aligner, then the models can be quickly produced, but the production speed is limited by the need to manufacture each model from scratch

Engineering Contradiction:

Improverapid production capabilityVSAvoidproduction speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The base model containing the receptacle and die is manufactured in advance and can be reused for multiple patients. This preliminary action eliminates the need to repeatedly manufacture the same structural components, allowing only the patient-specific overlay data to be processed quickly through additive manufacturing. This significantly increases production speed while maintaining the ease of manufacture benefit of additive technology.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By segmenting the model into reusable and patient-specific portions, the invention allows the reusable base to be manufactured once and then rapidly combined with different patient overlays. This segmentation enables parallel processing where multiple patient overlays can be prepared while the base model remains available, thereby increasing overall productivity without sacrificing the rapid production capability of additive manufacturing.

Inventive Principle:

Principle #1Segmentation

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

This approach reduces polymer waste by enabling the reuse of the die and minimizing the volume of custom models produced, thereby decreasing environmental impact and potentially increasing production speed.

Implementation Method 1

the reusable die is configured to stabilize and rigidify said dental model for thermoforming a dental aligner from polymer sheet material thereon

Methodology Applied

Scientific EffectRigidification:

Implementation Method 2

thermoforming a dental aligner from the polymer sheet material on the model and die assembly

Methodology Applied

Scientific EffectThermoforming:

Data Source

PatentUS11524445B2Dental model and reusable die assembly for thermoforming of dental aligners

Publication Date: 2022.12.13 CARBON INC

AI summary

An assembly useful for thermoforming a dental aligner from polymer sheet material includes (a) a custom dental model having a planar bottom surface and a receptacle formed in said planar bottom surface; and (b) a reusable die removably received in said receptacle.