Virtual Denture Design and Additive Manufacturing for Fit Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The traditional process of fabricating dentures is time-consuming and costly, requiring multiple visits between patients and healthcare professionals, with potential inaccuracies in fit and aesthetics due to manual methods and the need for repeated adjustments.
Innovation Solution
A method using computer-aided design (CAD) and computer-assisted manufacturing (CAM) to create virtual denture designs based on patient anatomy, followed by additive manufacturing to produce a functional fitting replica denture, which reduces the number of steps and improves accuracy by replicating unique oral anatomy features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual methods are used to fabricate dentures, then the process allows for flexibility and adjustment, but the time required and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by creating a virtual denture design and physical model before final denture fabrication. The virtual design phase allows all adjustments to be made digitally, and the physical model serves as a preliminary prototype for patient evaluation, eliminating the need for multiple manual adjustments later in the process.
Solution Approach 2:
The patent uses copying by creating a physical model that replicates the patient's oral anatomy and a virtual copy of the denture design. This physical model copy allows for accurate representation and evaluation of the final denture fit and appearance before actual manufacturing, reducing the need for rework.
2Manufacturing precision
If multiple patient visits are scheduled for impressions, try-ins, and adjustments, then the fit and aesthetics can be evaluated, but the overall treatment time and cost increase
Solution Approach 1:
The patent performs preliminary evaluation by creating a physical model of the virtual denture design that can be placed in the patient's mouth before final fabrication. This allows the patient and dentist to evaluate fit, appearance, and bite relationship in advance, identifying and correcting any issues before the actual dentures are made, thereby reducing the need for multiple adjustment visits.
Solution Approach 2:
The patent introduces a physical model as an intermediary between the virtual design and the final denture. This physical intermediary allows for tangible evaluation and adjustment of the design in the patient's mouth without committing to final fabrication, serving as a test version that can be modified before producing the actual dentures.
3Measurement precision
If wax try-ins are used to evaluate bite registration, then the bite relationship can be assessed, but the wax may be damaged and require remanufacturing
Solution Approach 1:
The patent uses composite materials by combining a rigid structural component with a resilient material for the bite registration portion. This allows the try-in denture to maintain its shape and structural integrity while providing accurate bite assessment, preventing damage that would require remanufacturing.
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
This approach significantly reduces the time and cost of denture production, enhances accuracy and fit, and allows for more precise evaluation of bite registration without damaging wax, leading to a more efficient and patient-specific denture creation process.
Implementation Method 1
Additive manufacturing processes include those known by terms such as three-dimensional (3D) printing, additive manufacturing, rapid prototyping and rapid manufacturing, and include processes of forming a three-dimensional solid objects from a virtually designed digital model.
Data Source
AI summary
The present application describes a method for designing and manufacturing a denture device for a patient. A method is described for designing a virtual denture and manufacturing a denture device from the virtual denture. An apparatus is prepared having a denture teeth set-up that corresponds to a pre-designed denture teeth design and a denture base that comprises patient specific information. The methods and apparatus described herein reduce the number of visits required to manufacture a denture device.