Thermoformed Orthodontic Aligners With Predictable Thickness
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Solution Overview
Problem
Conventional thermoforming methods for manufacturing orthodontic aligners result in inconsistent and unpredictable thickness, leading to ineffective orthodontic treatments and increased time and cost due to the need for repeated attempts to achieve the desired aligner configuration, which is further complicated by the variability in dental arch shapes between individuals.
Innovation Solution
A method and system that utilize a computer-implemented process to determine the optimal manufacturing parameters for thermoforming aligners by obtaining a 3D map of the dental archform, parsing it to determine specific property values, and adjusting the precursor aligner thickness and thermoforming parameters to achieve a desired aligner thickness, ensuring consistent and effective loading conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermoforming methods are used to manufacture orthodontic aligners, then the manufacturing process is simple and fast, but the aligner thickness becomes inconsistent and unpredictable
Solution Approach 1:
The patent applies preliminary action by calculating and determining the optimal precursor aligner thickness before the thermoforming process begins. The system computes the required precursor thickness based on the desired final aligner thickness, material properties, and thermoforming parameters, ensuring that the subsequent manufacturing process produces consistent results without requiring complex real-time adjustments during forming.
Solution Approach 2:
The patent employs parameter changes by systematically varying and optimizing multiple parameters including precursor aligner thickness, thermoforming temperature, pressure, and time. The system establishes relationships between these parameters and the final aligner thickness, allowing precise control over the manufacturing outcome by adjusting specific parameters rather than relying on the entire process complexity.
2Manufacturing precision
If experimental variation of thermoforming parameters is performed to achieve desired aligner thickness, then the desired thickness can be obtained, but the process requires multiple failed attempts and increases time and cost
Solution Approach 1:
The system performs preliminary calculations to determine the optimal precursor aligner thickness and thermoforming parameters before actual manufacturing. By pre-computing the required parameters based on desired outcomes and material properties, the system eliminates the need for multiple experimental attempts and failed iterations, significantly reducing the time required to achieve the desired aligner thickness.
Solution Approach 2:
The patent implements feedback mechanisms by measuring the actual aligner thickness produced and using this information to adjust and optimize subsequent manufacturing parameters. The system establishes a feedback loop where measurement data from previous runs informs parameter adjustments for future production, enabling continuous improvement and consistent achievement of target thickness without repeated failed attempts.
3Reliability
If conventional thermoforming methods are used, then the manufacturing process is straightforward, but the resulting aligners produce variable and unpredictable loading conditions on teeth
Solution Approach 1:
The system applies preliminary action by calculating the optimal precursor aligner thickness and manufacturing parameters before production to ensure consistent final aligner thickness. This pre-planning approach guarantees reliable and predictable loading conditions on teeth, as the aligner geometry and thickness are precisely controlled from the outset, eliminating the variability that would otherwise compromise treatment effectiveness.
Solution Approach 2:
The patent uses parameter changes to optimize the relationship between precursor thickness, thermoforming conditions, and final aligner properties. By systematically adjusting and controlling these parameters, the system ensures that aligners produce consistent and predictable loading conditions on teeth, maintaining treatment reliability while preserving manufacturing simplicity through standardized parameter sets.
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 solution enables the production of aligners with consistent thickness and improved orthodontic loading conditions, reducing the need for iterative processes and enhancing the efficiency and effectiveness of orthodontic treatments by ensuring the aligners can withstand intended loading conditions.
Implementation Method 1
a heating element arranged for heating the precursor aligner to a desired thermoforming temperature value
Implementation Method 2
a platform movable along a thermoforming axis for placing the precursor aligner thereon, and a heating element arranged for heating the precursor aligner to a desired thermoforming temperature value
Data Source
AI summary
Method for determining a manufacturing parameter for making an aligner with a desired aligner thickness using a thermoforming device operable for making the aligner by shaping a precursor aligner into the aligner using a mold representative of a dental archform, the method comprising: obtaining a 3D map associated with the dental archform; parsing the 3D map to determine a first property value and a second property value, the first property value being based on the 3D map and the second property value being derived from a 2D projection of the 3D map, and determining a thickness of the precursor aligner for obtaining the desired aligner thickness based on a ratio of the first property value and the second property value and a given value of an operating parameter of the thermoforming device; and sending instructions to the thermoforming device to make the desired aligner based on the determined operating parameter.