Variable-Stiffness Dental Appliance for Precise Tooth Force Control
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Solution Overview
Problem
Prior orthodontic appliances with homogeneous material properties lack control over force application to teeth, are sensitive to manufacturing tolerances, and have accuracy and cost issues in attachment placement and appliance manufacturing.
Innovation Solution
The development of orthodontic appliances with heterogeneous properties, featuring a stiff outer shell and a compliant inner structure, which allows for customized force and torque application to different teeth subsets, and improved manufacturing methods for accurate and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If orthodontic appliances use homogeneous material properties, then manufacturing is simpler, but control over force application to different teeth is insufficient
Solution Approach 1:
The patent applies local quality by creating regions within the appliance with different material properties. Specifically, it uses a first material for the outer shell and a second material with different stiffness for the inner structure, allowing different portions of the appliance to exert different forces on different teeth or groups of teeth, thereby achieving customized force control while maintaining manufacturability through layered construction
2Strength
If orthodontic appliances use stiff material, then structural strength is improved, but sensitivity to manufacturing tolerances increases
Solution Approach 1:
The patent employs composite materials by combining a first material for the outer shell with a second material for the inner structure. The outer shell material provides structural strength and rigidity, while the inner structure material with different stiffness characteristics compensates for manufacturing tolerances and ensures accurate force application, thereby reducing overall sensitivity to manufacturing variations
3Device complexity
If orthodontic appliances use single-material construction, then device complexity is reduced, but accuracy of force application deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the appliance into distinct regions: an outer shell made of first material and an inner structure made of second material. This segmentation allows each region to be optimized for its specific function - the outer shell for structural integrity and the inner structure for precise force application - thereby achieving accurate force control without excessive overall complexity
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
Enhances the accuracy and reliability of tooth movement with consistent force application, reducing sensitivity to manufacturing tolerances and improving the efficiency of appliance production and placement.
Implementation Method 1
an inner structure having a stiffness different than a stiffness of the outer shell. The inner structure may be positioned on an inner surface of the outer shell to distribute the one or more of a force or a torque to at least one tooth received within the plurality of cavities
Data Source
AI summary
Methods for fabricating dental appliances and associated systems are provided. In some embodiments, a method includes defining a plurality of object cross-sections of a dental appliance, and sequentially polymerizing the plurality of object cross-sections to create the dental appliance. The dental appliance can include an outer shell having a plurality of teeth-receiving cavities, and an inner structure coupled to an inner surface of the outer shell. The outer shell can have a first stiffness, and the inner structure can have a second stiffness less than the first stiffness. The sequential polymerization can include integrally forming the outer shell concurrently with the inner structure.