Rotary Dental Aligner Thermoforming With Sensor-Guided Heating
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Solution Overview
Problem
Existing dental aligner thermoforming apparatuses face challenges with high operator time requirements, suboptimal heating, and inconsistent quality due to manual handling and timed heating, leading to inefficient production of multiple aligners.
Innovation Solution
A rotary table-based apparatus with multiple operating modules that automatically moves between heating and moulding positions, equipped with a contactless sensor to optimize heating and a gas circulation system for rapid cooling, allowing simultaneous processing of multiple aligners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual handling is used to move the thermoformable sheet between heating and moulding stations, then the apparatus structure is simpler, but the operator time and production efficiency deteriorate
Solution Approach 1:
The apparatus is divided into multiple working stations (heating station, moulding station, cooling station) arranged sequentially on a rotary table. Each station performs a specific function independently, allowing continuous processing while the operator only needs to load and unload at the loading/unloading station. This segmentation resolves the contradiction by automating intermediate steps while keeping the overall structure manageable.
Solution Approach 2:
The rotary table serves multiple functions: it positions the mounting support at different working stations, enables automatic transfer between stations, and coordinates the timing of heating, moulding, and cooling operations. This multi-functionality reduces the need for separate manual handling mechanisms while maintaining structural simplicity.
2Device complexity
If timed heating is used for the thermoformable sheet, then the heating process is simpler to control, but the heating quality and aligner consistency deteriorate
Solution Approach 1:
A contactless sensor is implemented to detect the actual temperature or heating state of the thermoformable sheet in real-time. This feedback is transmitted to the control unit, which adjusts the heating duration and power dynamically. This resolves the contradiction by replacing simple timed control with intelligent feedback-based control that ensures consistent heating quality without excessive complexity.
Solution Approach 2:
The heating control system transitions from static timed control to dynamic adaptive control. The heating parameters (duration, power) are adjusted in real-time based on the actual state of the thermoformable sheet detected by the contactless sensor, ensuring optimal heating quality for each cycle while maintaining manageable system complexity.
3Productivity
If multiple aligners are processed simultaneously on a single enlarged head, then the productivity improves, but the heating uniformity and aligner quality deteriorate
Solution Approach 1:
Instead of processing multiple aligners simultaneously on one enlarged head, the apparatus segments the production into multiple sequential stations on a rotary table. Each station processes one aligner at a time with dedicated heating, moulding, and cooling resources, ensuring uniform heating quality while maintaining overall high productivity through continuous operation across multiple stations.
Solution Approach 2:
The system transitions from processing multiple aligners in parallel (spatial dimension) to processing them sequentially in time (temporal dimension) through the rotary table's rotation. This dimensional shift allows each aligner to receive focused, uniform heating while the system maintains high throughput by continuously cycling through multiple stations, effectively resolving the contradiction between productivity and heating uniformity.
4Extent of automation
If the mounting support is moved manually between stations, then the automation level is lower, but the device complexity and operator intervention requirements worsen
Solution Approach 1:
The rotary table is designed as a multi-functional platform that simultaneously achieves multiple objectives: it positions the mounting support at different working stations, provides automatic transfer between stations, and coordinates the timing of various processing operations. This consolidation of functions into a single mechanism achieves high automation without proportionally increasing device complexity.
Solution Approach 2:
The apparatus merges the positioning, transfer, and coordination functions into a single rotary table mechanism. This consolidation eliminates the need for separate manual handling operations and multiple independent automation mechanisms, achieving effective automation while keeping the overall device structure manageable and relatively simple.
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
Reduces operator time significantly, ensures optimal heating, and improves aligner quality by enabling continuous production with minimal human intervention and precise temperature control.
Implementation Method 1
a heating device for heating the thermoformable sheet is present housed in the relative mounting support
Implementation Method 2
equipped with a contactless sensor to optimize heating
Implementation Method 3
a gas circulation system for rapid cooling
Implementation Method 4
in which a vacuum/overpressure is created to execute the thermoforming of said thermoformable sheet
Data Source
AI summary
An apparatus (1) for thermoforming dental aligners provides a support structure (10) on which a rotary table (11) is mounted on which a plurality of operating modules (20) are mounted at an equidistant angle, each comprising a moulding support (21) suitable to house a dental arch (I) and a mounting support (22) suitable to house a disc of thermoformable material (F). The rotation of the table (11) brings the operating modules (20) in succession, at a heating device (30) in which the disc (F) is heated and softened and then at a moulding device (40) in which the mounting support is lowered into a lowered position (PA) to realize a moulding chamber (41) in which by means of an overpressure the disc (F) goes to copy the shape of the dental arch (I) to realize an aligner. An operator can load all the operating modules (20) and start the apparatus (1) in an automatic cycle, which sequentially produces all the aligners without the apparatus needing to be manned by the operator.