3D-Printed Orthodontic Aligners with Smart Sensors for Sleep Apnea
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Solution Overview
Problem
Conventional orthodontic aligner systems, such as INVISALIGN, face challenges including high manufacturing costs and time due to the need for multiple molds and thermoforming processes, which result in inaccurate fittings, discomfort, and limited design flexibility, as well as the inability to effectively treat sleep apnea simultaneously with teeth straightening.
Innovation Solution
The development of 3D-printed orthodontic aligners with divot anchors and smart sensors connected to a control module system, allowing for direct manufacturing of aligners with customizable designs, improved anchoring mechanisms, and integration of sensors for treating sleep apnea and bruxism, reducing material waste and treatment time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermoforming processes with multiple molds are used to manufacture aligners, then manufacturing precision and fitting accuracy can be achieved, but manufacturing cost and treatment time increase significantly
Solution Approach 1:
The patent replaces the conventional mechanical thermoforming process with a 3D printing (additive manufacturing) process. This substitution eliminates the need for multiple physical molds and high-temperature thermoforming, directly manufacturing custom aligners with precise fittings through digital modeling and layer-by-layer deposition, thereby reducing both manufacturing time and cost while maintaining accuracy
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive/mechanical forming to additive manufacturing. By using 3D printing technologies with biocompatible materials, the system achieves the same or better fitting accuracy without requiring multiple molds and extensive post-processing, significantly improving productivity and reducing treatment time
2Adaptability or versatility
If conventional aligner systems are used for teeth straightening, then orthodontic treatment can be provided, but the ability to treat sleep apnea simultaneously is lost
Solution Approach 1:
The patent integrates multiple functions into a single aligner device. The 3D-printed aligner incorporates both orthodontic features (custom tooth alignment surfaces, anchoring mechanisms) and sleep apnea treatment features (mandibular advancement capability, airway support structures). This allows simultaneous treatment of both conditions with one device rather than requiring separate appliances
Solution Approach 2:
The patent merges two previously separate treatment systems (orthodontic aligners and sleep apnea devices) into a unified appliance. By combining the tooth-straightening function with the mandibular advancement function in a single 3D-printed structure, the system reduces the quantity of separate devices needed while maintaining adaptability to treat both conditions effectively
3Strength
If traditional manufacturing processes are used for aligners, then structural integrity can be ensured, but material waste and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by varying the material properties and thickness of the aligner in different regions through 3D printing. Areas requiring higher strength (such as anchoring zones and load-bearing surfaces) receive denser material deposition or reinforced structures, while less critical areas use thinner material. This optimized distribution maintains overall structural integrity while minimizing total material usage and waste
Solution Approach 2:
The patent replaces conventional mechanical manufacturing (which generates significant material waste through subtractive processes) with additive 3D printing. This substitution builds aligners layer-by-layer with precise material placement, eliminating the need for excess material removal and significantly reducing material waste while ensuring structural integrity through controlled deposition
Data Source
AI summary
A dual-purpose Oral Appliances having smart sensors and control module for treating sleep apnea and simultaneously straightening the teeth or reducing the bruxism or reducing the TMJ disorder are disclosed. The appliance contains upper and or lower teeth trays with or without air passageway. The appliance can be with or without external housing. The episodes of sleep apnea are reducing by one or combination of several mechanisms such as mandibular advancement (MAD), air stimulation by control of inhaled air flow bypassing the tongue and or micro-holes in air passageways, neuro/muscle electric stimulation of tongue and sleep position training. The sensors located inside or outside of the mouth, measure physiological and or biological and or chemical aspects of the patients. The sensors are connected to control module system consists of battery, microprocessor, and data transmission technologies.