3D-Scanned Shape Memory Retainers for Stable Tooth Contact
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Solution Overview
Problem
Conventional retainer manufacturing methods using stainless steel materials face challenges such as deformation, difficulty in achieving complete contact with multiple teeth, and increased manufacturing time and cost due to shape deviations and additional processing requirements.
Innovation Solution
A manufacturing method for a retainer using a shape memory alloy material, where three-dimensional scanning data of the teeth arrangement is processed to generate laser cutting shapes, allowing for the creation of a body part with a curved shape that is in stable contact with the teeth, without the need for additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a retainer body part is manufactured by laser cutting a shape memory alloy material based on conventional teeth surface height data, then the manufacturing process is simplified, but the body part cannot achieve complete close contact with multiple teeth due to interference and gaps caused by differences in inclination and flexure at each tooth position
Solution Approach 1:
The patent transitions from two-dimensional planar design to three-dimensional curved surface design. The body part is designed with a curved shape that follows the three-dimensional topology of the teeth arrangement, allowing simultaneous contact with multiple teeth at different heights and angles. This dimensional change enables the laser-cut body part to achieve complete close contact with all teeth without interference or gaps.
2Ease of manufacture
If a retainer is manufactured by bending stainless steel material to match plaster model shape, then the manufacturing process is traditional and manual, but the retainer is easily deformed and difficult to maintain complete contact with multiple teeth
Solution Approach 1:
The patent replaces the manual mechanical bending process with automated laser cutting. The shape memory alloy material is laser-cut according to the three-dimensional scanned data of the actual teeth arrangement, eliminating the need for manual bending and plaster model matching. This substitution ensures consistent shape accuracy and eliminates deformation issues associated with manual manipulation.
Solution Approach 2:
The patent changes the material parameter from conventional stainless steel to shape memory alloy. This material parameter change provides superior shape stability and memory characteristics, allowing the retainer to maintain its designed curved shape and continue contacting all teeth even under oral conditions. The shape memory alloy resists deformation better than traditional stainless steel.
3Manufacturing precision
If additional shape processing is performed to achieve stable contact between laser-cut body part and teeth, then contact accuracy is improved, but manufacturing time and cost are significantly increased
Solution Approach 1:
The patent performs preliminary action by accurately designing the body part shape in advance based on three-dimensional scanning data of the actual teeth arrangement. The curved shape is pre-calculated to account for all variations in tooth inclination and flexure. This preliminary precise design eliminates the need for subsequent shape processing adjustments, achieving both high contact accuracy and manufacturing efficiency in a single laser cutting step.
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 method enables the production of retainers that maintain stable contact with the teeth, reducing manufacturing time and cost, while ensuring accurate fit and improved correction effects by utilizing the shape memory alloy's ability to remember and maintain the desired shape.
Implementation Method 1
a process of acquiring three-dimensional scanning data of the teeth arrangement by using a three-dimensional scanning device
Implementation Method 2
a laser cutting process in which a body forming part configuring the body part is manufactured by laser cutting a base material formed of a shape memory alloy material
Implementation Method 3
a retainer to which a shape memory alloy is applied has been developed so as to prevent a deformation of a retainer
Data Source
AI summary
Proposed is a manufacturing method of a retainer provided with a body part having a first surface being in contact with a teeth surface of a plurality of teeth forming a teeth arrangement so as to support the teeth arrangement. The manufacturing method includes a process of acquiring three-dimensional scanning data of the teeth arrangement, a data processing process in which processing line data for manufacturing the body part are generated, and a laser cutting process in which a body forming part is manufactured from a base material formed of a shape memory alloy material. In the data processing process, tangential lines that extend along the teeth surface of the teeth arrangement are formed and collected, and a first processing line formed by connecting, to each other, tangential line portions in a tangential line group body and a second processing line spaced apart from the first processing line are generated.