Robotic Aligner Feature Formation via Localized Thermoforming
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Solution Overview
Problem
Current orthodontic aligner fabrication methods are limited in their ability to efficiently and accurately create complex features and modifications, such as rotational corrections and auxiliary devices, which are necessary for effective tooth movement and treatment progression, often requiring manual intervention and multiple aligners.
Innovation Solution
A robotic system that integrates servo and stepper motors, sensors, and CAD/CAM software to automate the formation of features in orthodontic aligners, allowing for precise thermoforming, trimming, and the creation of identifying markings, as well as the installation of auxiliary devices like tacks and hooks, using a combination of heating stations and thermoforming stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used to create features in orthodontic aligners, then flexibility in design is maintained, but manufacturing precision and productivity deteriorate
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses computer-controlled heating elements and forming tools. The robotic system can precisely position and apply heat to specific regions of the aligner material, then mechanically form features with high precision without manual intervention, thus improving manufacturing precision while accepting increased system complexity.
Solution Approach 2:
The patent utilizes controlled temperature changes as a key parameter to enable feature formation. By precisely controlling the heating process and thermal parameters, the system can locally soften the aligner material to allow forming of complex features, then cool it to set the desired shape, achieving high precision feature formation through parameter control.
2Productivity
If multiple aligners are used to achieve desired tooth movement, then treatment effectiveness is maintained, but the number of aligners and treatment time increase
Solution Approach 1:
The patent applies preliminary action by pre-forming activation features, auxiliary device attachment points, and other modifications into the aligner material before the aligner is delivered to the patient. This preliminary formation of features allows the aligner to be more effective with fewer units, as each aligner can incorporate multiple functional elements that enhance tooth movement capability without requiring additional aligners in the sequence.
3Extent of automation
If automated robotic systems are implemented for aligner modification, then productivity and precision improve, but device complexity and initial cost increase
Solution Approach 1:
The robotic system is designed with multi-functionality to justify its complexity. It can perform multiple operations including heating, forming, trimming, and marking on the aligner material using a single integrated system. This universality reduces the need for multiple separate devices and processes, making the increased automation worthwhile despite the initial complexity investment.
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 the efficient and precise modification of aligners, reducing the need for manual intervention, minimizing the number of aligners required, and allowing for more consistent and controlled tooth movement, thereby enhancing the effectiveness and efficiency of orthodontic treatment.
Implementation Method 1
A selected region of an aligner is heated above its thermoforming temperature by a heating station (e.g., a laser, hot air pencil, or electrically-heated die)
Implementation Method 2
A laser station can also be used to trim excess material from the aligner or to cut features into the aligner
Data Source
AI summary
A robotic system for forming features in orthodontic aligners includes a control system, a platen for three-dimensional positioning of the aligner, a heating station for selectively heating a small region of the aligner, and a thermoforming station for manipulating the heated region to form a desired feature in the aligner. Optionally, a laser cutting and trimming station can also be included to trim excess material from the aligner or to cut features into the aligner. The control system can include a processor with CAD software to enable a user to design features for aligners.