method to treat an individual

专利摘要:
Systems and methods are revealed to treat teeth to correct malocclusions. This may be accomplished in a variation by receiving a scanned dental model of an individual's dentition, determining a treatment plan having a plurality of additional movements to reposition one or more of the individual's dentition teeth, and fabricating one or more aligners. which correlates to a first subset of the plurality of additional movements.
公开号:BR112019012775A2
申请号:R112019012775
申请日:2017-10-19
公开日:2019-12-10
发明作者:Wen Huafeng
申请人:Ulab Systems Inc；
IPC主号:

专利说明:

METHOD FOR TREATING AN INDIVIDUAL CROSS-REFERENCE TO RELATED APPLICATIONS [001] This application is a continuation of North American Patent Application 15 / 386,280, filed on December 21, 2016, which is partly a continuation of the North American Patent Application 15 / 230,139, filed on August 5, 2016, which claims priority benefit to North American Provisional Application 62 / 238,554, filed on October 7, 2015; a partial continuation of US Patent Application 15 / 230,170, filed on August 5, 2016, which claims priority benefit to US Provisional Application 62 / 238,560, filed on October 7, 2015; a continuation in part of US Patent Application 15 / 230,193, filed on August 5, 2016, which claims priority benefit to US Provisional Application 62 / 238,532, filed on October 7, 2015; a partial continuation of US Patent Application 15 / 230,216, filed on August 5, 2016, which claims priority benefit to US Provisional Application 62 / 238,514, filed on October 7, 2015; and partly a continuation of US Patent Application 15 / 230,251, filed on August 5, 2016, which claims priority benefit to US Provisional Application 62 / 238,539, filed on October 7, 2015. Each of those orders is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION [002] The present invention relates to methods and apparatus for computerized orthodontics. More particularly, the present invention relates to methods and apparatus for planning orthodontic treatments and manufacturing one or more dental devices, such as retainers and aligners using printing processes.
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2/111 three-dimensional (3D).
HISTORY OF THE INVENTION [003] Orthodontics is a specialty of dentistry that refers to the study and treatment of malocclusions that can result from dental irregularities, disproportionate skeletal-facial relationships, both. Orthodontics treats malocclusion by displacing teeth through bone remodeling and facial growth control and modification.
[004] This process has traditionally been performed by using static mechanical force to induce bone remodeling, thereby allowing the teeth to move. In this approach, devices having an arch interface with supports are attached to each tooth. As the teeth respond to the pressure applied through the arches when changing their positions, the wires are tightened again to apply additional pressure. This widely accepted approach to treating malocclusions takes an average of twenty-four months to complete, and is used to treat several different classifications of clinical malocclusion. Treatment with braces is complicated by the fact that it is uncomfortable and / or painful to patients, and orthodontic braces are perceived as non-aesthetic, all of which creates considerable resistance to use. Still, the treatment time cannot be shortened by increasing strength, as too high strength results in root resorption, as well as being more painful. The average treatment time of twenty-four months is very long, and further reduces the use. In fact, some estimates provide that less than half of the patients who could benefit from this treatment are eligible to continue with orthodontics.
[005] Kesling introduced the tooth positioning device in 1945 as a method of refinement
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3/111 of the final use of orthodontics that ends after the removal of the braces (breakdown). The positioner was a flexible one-piece rubber device manufactured in wax configurations designed for patients whose basic treatment was completed. Kesling also predicted that certain greater tooth movements could also be performed with a series of positioners manufactured from sequential tooth movements in the configuration, as treatment progressed. However, this idea did not become practical until the advent of three-dimensional (3D) scanning and use of computers by companies, including Align Technologies and also OrthoClear, ClearAligner, and ClearCorrect to provide much improved aesthetics, since the devices are transparent.
[006] However, for a traditional finishing model for an individual tooth, the gingival geometry is lost and the false gingiva is recreated, usually remodeled by a technician. As a result, the gingival geometry may not be accurate in the first instance and an animation of gum changes over time due to the lack of a physical model is even more difficult to model. This inaccurate modeling causes the resulting aligner to be out of adjustment, resulting in devices that are too large or too small, resulting in patient discomfort.
[007] Another problem is that without the real gingiva as the reference, some so-called modeled treatments cannot be achieved in reality, resulting in possible errors, for example, a tooth movement within a bad modeled gingiva may occur, however, the tooth movement can, in fact, be moved outside of a patient's real gingival.
[008] Another problem of finishing and filling voids and creating an individual tooth and gingival model, there is little information that can define the
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4/111 real limit of two teeth. These finish and fill models force the boundary surfaces to be defined even if they are arbitrary.
[009] Depending on which boundary surface is defined, movement can be restricted or loose, which means that some real life movement can be achieved; however, due to these inaccuracies, the modeling software is unable to model precisely, due to the models colliding with each other. This can cause the result of the treatment to create gaps between the teeth and additionally need final improvements, which increases the cost and dissatisfaction of the patient. On the other hand, if the modeled movement is loose, the software can allow movements that are physically impossible in reality and this can cause the modeled device to push its teeth towards each other, unable to move. This can also cause the plastic protector on the aligner to sometimes stretch a lot, so that the protector applies an uncomfortable amount of force, which could be painful for the patient.
[0010] Another problem with the finishing and filling of voids is the filling of the geometry like a real tooth, downwards, the lines below are probably of modeled boundary surfaces, these models look like a real tooth; however, these sharp edges cause deeper lower cuts which, once printed and thermally formed to have plastic protection, make removing plastic protection from the printed model difficult due to deep lower cuts. To compensate for this, a facet object is typically created to fill the pin increasing inaccuracy and costs.
[0011] Another problem with finishing and filling the void is that the model size is too big
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5/111 to communicate between the user and the manufacturer, thus needing the model size to be reduced, resulting in the absence of model details. These inaccuracies could mislead professionals, for example, the complex complete model may not have a gap between two adjacent teeth, however, the reduced model may have.
[0012] These treatments with 3D scanning and computerized planning are complicated and take time. Accordingly, there is a need for an effective and cost-efficient procedure for planning a patient's orthodontic treatment.
SUMMARY OF THE INVENTION [0013] In the treatment of a patient to correct one or more conditions with his or her teeth, the steps of digitally scanning the patient's teeth, treatment planning and / or optionally manufacturing treatment devices, such as aligners, for correct the placement of one or more teeth, can be performed directly at the service provider's office.
[0014] A method for treating an individual, as described herein, can generally comprise receiving a scanned dental model of an individual's dentition, determining a treatment plan having a plurality of additional movements to reposition one or more dentition teeth of the individual, and fabrication of one or more aligners that correlates to a first subset of the plurality of additional movements.
[0015] In a variation, this may include reevaluating the individual's dentition after a predetermined period of time to monitor the repositioning of one or more teeth.
[0016] In another variation, this may include manufacturing one or more additional aligners
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6/111 that correlate to a second subset of the plurality of additional movements.
[0017] In another variation, this may include treating one or more teeth by means of a corrective measure without an aligner.
[0018] In another variation, this may include receiving an entry from the individual regarding the treatment plan.
[0019] In another variation, the determination of the treatment plan may also include application of a marking to one or more teeth within the dental model, simulation of a process of rolling spheres along the outside of one or more teeth and gums within the dental model, determining a boundary between each of the one or more teeth and gums based on a path or trajectory of the rolling ball process, assigning a rigid or soft region to each of the one or more teeth and gums within the dental model, and moving a position of one or more teeth within the dental model to correct malocclusions in the development of a treatment plan.
[0020] In another variation, the determination of the treatment plan can also comprise determination of a movement for a plurality of digital tooth models in the dental model to correct malocclusions through a tooth movement management module, assigning a sphere of influence on each tooth model to establish a proximity distance between each tooth model by means of a collision management module, monitoring the real state of each individual tooth, comparing the real state of each tooth in relation to to an expected state of each tooth model using a tooth management module, and adjusting the movement of one or more
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7/111 teeth based on a comparison of the real state and the expected state if a deviation is detected.
[0021] In another variation, the manufacture of one or more aligners may also comprise generation of a free-form structure having a reticular structure that corresponds to at least part of a dentition surface, in which the reticular structure defines a plurality of spaces open, so that the free-form structure is at least partially transparent, and fabrication of the reticular structure by impregnating or covering a coating on or over the reticular structure, so that the mouthpiece is formed.
[0022] In another variation, the manufacture of one or more aligners may also comprise manufacture of a support structure that corresponds to an external surface of the dentition, formation of one or more buccal appliances on an outer surface of the support structure, so that an interior of the one or more oral appliances conforms to the dentition, and removal of the support structure from the interior of the one or more oral appliances.
[0023] In another variation, the manufacture of one or more aligners may also comprise calculation of a cutting loop path based on the model rule for determining a path to finish a mold that replicates the patient's dentition, application of a cutting handle overlay wall on the model to reduce model complexity, determining a position of a cutting instrument in relation to the mold for finishing the mold, generating a computer numerical control code based on the overlay wall and position of the cutting instrument, and mold making based on the computer generated numerical control code.
[0024] Systems and methods are revealed for
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8/111 treating teeth to correct malocclusions. This can be accomplished by applying a series of markings to a digital dental model and applying a rolling ball process to identify tooth boundaries that separate a tooth from a neighboring tooth. The ball bearing process can also be used to determine the crown / gingival margin. The user can also assign regions to the dental model to indicate rigid regions (rigid regions have a criterion in which they cannot change their shape) and soft regions (soft regions have a criterion in which they can deform with an included rigid region). With the marked and defined dental model, the user can then generate a treatment plan to move the marked or defined teeth or teeth in relation to each other to correct any malocclusions. Upon approval of the treatment plan, a series of 3D printed dental appliances or aligners to be used in series by the patient can be manufactured to ultimately move the tooth or teeth to a desired position.
[0025] A method for planning a treatment to correct malocclusions may, in general, comprise receiving a scanned dental model of an individual's dentition and then applying a mark to one or more teeth within the dental model. The rolling ball process can be simulated along an exterior of the one or more teeth and gums within the dental model to determine a boundary between each of the one or more teeth and gums based on a path or trajectory of the process ball bearing. The hard or soft regions can be assigned to each one of the one or more teeth and gums within the dental model and a position of the one or more teeth within the dental model can be moved by the user to correct malocclusions in the dental model.
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9/111 development of a treatment plan. Once approved (for example, by the patient and / or user), one or more prostheses or aligners can be manufactured to move the one or more teeth according to the treatment plan.
[0026] Moving a position of one or more teeth in the development of the treatment plan usually involves changing a new dental model of the dental model. As described, one or more prostheses or aligners can be manufactured, for example, through 3D printing of one or more aligners, so that this whole process can be carried out in a single visit by the individual to a dental office.
[0027] In another example to plan a treatment to correct malocclusions, the method can, in general, comprise directly scanning an individual's dentition to create a digitized dental model and having the user apply a mark to one or more teeth within the dental model. The simulated sphere can be digitally rolled along the exterior of one or more teeth and gums within the dental model to determine a boundary between each of the one or more teeth and gums based on a process path or trajectory. ball bearing. The rigid region can be attributed to each one of the one or more teeth and the soft region can, in a similar way, be attributed to the gums within the dental model. Then, a position of one or more teeth can be moved within the dental model to correct malocclusions in the development of a treatment plan.
[0028] As described, once the treatment plan has been approved (for example, by the patient and / or user), one or more prostheses or aligners can be manufactured to move the one or more teeth according to
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10/111 the treatment plan and this whole process can be performed in a single visit by the individual to a dental office.
[0029] Advantages of the system may include one or more of the following. The system allows strict control by the treatment professional at each stage by allowing specific movements from one stage to the next stage. In one example, it is desirable, in some configurations, to synchronize the movement and operation of individual tooth models to have few tooth models that operate in a choreographed manner, as dictated by a treatment professional. Having this choreographed movement is typically not possible through manual control, in which the tooth models move randomly and independently. The present method and / or control system are ideal for use in moving different tooth models and to provide synchronized tooth movement. This method can be non-colonies to avoid any collisions between the teeth and also to prevent the appearance of merely random movements, at least in some applications. On the contrary, it is desirable that the tooth models react with each other in a safe manner to environmental conditions, such as changes in bone structure and soft tissue during tooth movement in a group of choreographed tooth models.
[0030] The system is also provided to control the movement of the tooth of a plurality of biological objects (tooth models). The system includes a plurality of tooth models, each including a control code that controls its movement. The system also includes a tooth movement control system (SCMD) with a processor that runs a dental administrator module and with memory that classifies a different tooth movement plane for each tooth model. In practice,
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11/111 tooth movement is stored in the memory of each tooth model (for example, a different tooth movement plane for each tooth model). Then, during tooth movement operation, each of the local control modules independently the tooth model to execute the tooth movement plane stored in the tooth model memory.
[0031] In some cases, the local control module of each tooth model operates to periodically compare a current position of the tooth model with the plane of movement of the tooth and, based on the comparison, modify the control of the tooth model tooth. In such cases, modification of the control may include changing a tooth movement speed or selecting a new path for the tooth model in the tooth movement plane as a target. In other cases, local control of each tooth model can operate to detect another tooth model within a safety envelope over the tooth model and, in response, communicate a collision alert message to the detected between the tooth models to make the detected one of the tooth models change its course to move the safety enclosure. In some specific implementations, the tooth models are teeth, and the local control module for each tooth model operates to detect tooth tilt and roll and, when the tilt or roll exceeds a predefined maximum, change the tooth operations. to a safe operating mode.
[0032] The description also teaches a method of controlling tooth movement. In this control method, an initial step can be to receive a plane of movement of the tooth exclusive to each of the teeth for a plurality of teeth. A next step may involve the operation
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Simultaneous 12/111 of the teeth to execute the tooth movement plans. The method further includes the provision of a communication channel between pairs of teeth with a first tooth detecting a second tooth in a predefined space next to the first tooth. The method also includes, with the first of the teeth, transmission of a message to the second tooth through the communication channel between the first and second teeth, causing the second tooth to change position to avoid collision.
[0033] In some implementations of the method, the plans of movement of the tooth may include a plurality of paths for each of the teeth. In these implementations, the method may also include, during the operation of the teeth to execute the tooth movement planes, adjustment of the tooth movement speed or stroke of one of the teeth based on the comparison of a current position and one of the paths. The tooth movement plans can also include a period of time elapsed for each of the paths, and then the speed of movement of the tooth or course can be adjusted when the elapsed time is exceeded by one of the teeth.
[0034] In some implementations of the method, tooth movements are decomposed into different movement metrics, for example, a tooth movement can be decomposed into a tip, rotation around the long axis, body movement etc. The artificial intelligence network, commonly, a neural network is incorporated, this network having different neurons and weights can be adjusted, where the treated cases are the set of knowledge of this neural network. When inserting each case and adjusting the weights of the net to make the net more predictable to the treatment result, when a new case arrives, the designated movement can be performed by the net and an ideal and more predictable movement design is
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13/111 reached. The more training cases provided, the more robust the network can be achieved.
[0035] Soft surface of gingiva, each tooth executes rules for a group to conform to one or more of the goals or objectives:
1. Adherence to the six Andrews Keys for Occlusion;
2. Root cannot move more than 0.5 mm per month;
3. According to a U or V formation;
4. Open the bite;
5. No interproximal reduction;
6. Avoid moving any implanted teeth;
7. Define a subgroup of teeth that move together as a unit.
[0036] The system allows strict control by the treatment professional at each stage by allowing specific movements from one stage to the next stage. In one example, it is desirable in some configurations to synchronize the movement and operation of the tooth models to have the tooth models operating in a choreographed manner, as dictated by a treatment professional, which is not possible through manual control, in the which tooth models move randomly and independently.
[0037] The present control method and / or system can be ideal for use in the movement of different tooth models and to provide synchronized tooth movement. This method would be non-collective, since it is desirable to avoid collisions and also to avoid the appearance of merely random movement (at least in some applications) of tooth models. On the contrary, it is desirable that the tooth models react with each other safely to
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14/111 environmental conditions, such as changes in bone structure and soft tissue during tooth movement in a group of choreographed tooth models.
[0038] Turning now to the manufacture of free-form structures including mouthpieces or aligners, a method for the manufacture of a mouthpiece can, in general, comprise capturing a three-dimensional representation of an individual's dentition and generating a free-form structure having a reticular structure that corresponds to at least part of a dentition surface, wherein the reticular structure defines a plurality of open spaces, so that the free-form structure is at least partially transparent. The reticular structure can then be manufactured by impregnating or covering a coating on or over the reticular structure so that the mouthpiece is formed.
[0039] One or more oral appliances can therefore be manufactured, in which each subsequent oral appliance is configured to grant movement of one or more teeth of the individual and is intended to be used by the individual to correct any malocclusions.
[0040] In general, the oral appliance can comprise a reticular structure that is configured to correspond to at least part of a surface of an individual's dentition, in which the reticular structure defines a plurality of open spaces, so that the structure free form is at least partially transparent. A coating can impregnate or cover the or on the reticular structure and at least one dental fixation structure can be formed as part of the reticular structure, where the dental fixation structure is located in the vicinity of the one or more teeth to be moved.
[0041] The system provides free-form structures
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15/111 that fit the surface of a body part, which are at least partially made by additive manufacturing. The freeform structures can comprise a basic structure that includes a reticular structure and a coating material provided therein. The reticular structure can be impregnated in and / or surrounded by the coating material which can include, for example, polymeric or ceramic materials and metals. In addition, the coating material may include different regions of varying thickness or other characteristics incorporated into the material. The polymer may include several different types, for example, silicone, polyurethane, polyepoxide, polyamides, or mixtures thereof. In alternative embodiments, the reticular structure can be impregnated in and / or surrounded by a solid foam.
[0042] In certain embodiments, the reticular structure can be defined by a plurality of unit cells with a size between, for example, 1 and 20 mm. In other embodiments, the lattice structure may be provided with varying unit cell geometries having varying cell dimensions and / or varying structure densities. In other embodiments, the lattice structure can be comprised of at least two separate lattice parts movably connected to each other and integrated into the structure.
[0043] In certain embodiments, the free-form structure may also include one or more external and / or internal sensors (for example, pressure and / or temperature sensors) and / or one or more external and / or internal markers (for example example, placeholders). These markers can be read externally to determine the current movement of the tooth to assist the professional in deciding future movement adjustments, if necessary.
[0044] In certain embodiments, the structure
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16/111 in free form can also include one or more agents disposed externally and / or internally, such as several chemical compounds or drugs, for example, tooth whitening materials, insulin that can be slowly released orally to a diabetic patient etc. . These chemicals, drugs, or medication can also be incorporated to loosen gums and / or tendons to allow teeth to move faster, wound treatments, etc.
[0045] In certain embodiments, the freeform structure may also comprise one or more external and / or internal locators, so that, when that device is misplaced, the user can use a mobile computer to detect the location and find the device. The locator can include any number of devices, for example, magnets, wireless proximity detectors, optical proximity detectors, etc.
[0046] Free-form structures can also be additionally configured to have different stiffness values in different regions of the structure using different configurations.
[0047] In one aspect, systems and methods for manufacturing one or more oral appliances are revealed by capturing a three-dimensional representation of an individual's body part, such as the dentition, and creating a removable internal support structure. One or more of the mouthpieces can be manufactured directly on one or more corresponding support structures. Once the oral appliance has been completed, the internal support structure can be removed to leave the dental appliance that fits over one or more teeth to correct malocclusions in the dentition.
[0048] A method for the manufacture of a mouthpiece can, in general, comprise the capture of
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17/111 a three-dimensional representation of an individual's dentition, fabrication of a support structure that corresponds to an external surface of the dentition, formation of one or more oral appliances on an external surface of the support structure, so that an interior of the one or more mouthpieces conform to the dentition, and removal of the support structure from the inside of the one or more mouthpieces.
[0049] The one or more oral appliances can be formed in a sequence configured to move one or more teeth of the individual to correct malocclusions. In addition, the support structure can be made of a first material and the one or more mouthpiece can be made of a second material other than the first material.
[0050] In general, the apparatus set may comprise the support structure having an outer surface that corresponds to an external surface of the individual's dentition, in which the support structure is made of a first material, and the oral apparatus formed on the outer surface of the support structure by means of three-dimensional printing, so that an interior of the formed mouthpiece conforms to the individual's dentition, in which the mouthpiece is made of a second material different from the first material.
[0051] The support structure is generally removable from the inside of the formed oral appliance, so that the oral appliance is positioned over the dentition. In addition, a plurality of oral appliances can be formed, in which each oral appliance is formed in a sequence configured to move one or more teeth of the individual to correct malocclusions. Accordingly, each mouthpiece can be formed on a plurality of corresponding support structures.
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18/111 [0052] The structures according to the present invention can have a different stiffness in different parts of the structure and can be made transparent, even if they are made, at least partially, by additive manufacturing. The free-form structures according to the present invention can still be made as a single part, and can also comprise internal or external sensors.
[0053] Systems and methods for cutting and finishing dental molds and oral appliances are revealed when receiving a digital model of teeth, determining a cutting loop path and applying an overlay wall to the cutting loop to generate a base of simplified tooth in a dental mold having an internal arc curve and an external arc curve. The mouthpiece can be formed on the dental mold and a cutter can be applied using a single tracking movement through the internal and external arc curves.
[0054] The system allows an easy way to cut and finish the tooth models. The system allows strict control by the treatment professional at each stage by allowing specific movements from one stage to the next stage. The system can form aligners quickly and efficiently, due to the simplification of the overlap wall. CNC machines can manufacture each guard as a customized device for many stages of tooth movement. The mold can be cut / finished using inexpensive 2D cutting machines, if necessary. In addition, the resulting mouthpieces (aligners, protectors, etc.) can be removed from the positive mold with minimal force, reducing the risk of excessive wear force protector wear.
[0055] In general, an achievement for a
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19/111 method of forming a mouthpiece can comprise a digital model of a patient's dentition, calculation of a cutting loop path based on the model's rule for determining a path to finish a mold that replicates the dentition of the patient, applying a cutting loop overlay wall to the model to reduce model complexity, determining a position of a cutting instrument in relation to the mold for finishing the mold, generating a computer numerical control code based on on the overlapping wall and position of the cutting instrument, and mold making based on the computer generated numerical control code.
[0056] Another realization for a method of forming a mouthpiece can, in general, comprise receiving a digital model of a patient's dentition, calculating a cutting loop path based on the rule in the model for determining a path for finishing a mold that replicates the patient's dentition, applying a cutting loop overlay wall on the model to reduce model complexity, determining a predetermined height of a model base, generating a numerical control code model computer, and mold making based on computer generated numerical control code.
BRIEF DESCRIPTION OF THE DRAWINGS [0057] The following description of the figures of specific embodiments of the invention is merely exemplary in nature and is not intended to limit the present teachings, their application or uses. Throughout all drawings, corresponding reference numbers indicate similar or corresponding parts and aspects.
[0058] Figure IA presents an exemplary process for scanning the patient's dentition, planning
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20/111 of treatment, and then manufacture of one or more aligners to effect treatment of the patient.
[0059] Figure 1B presents an example of a flowchart that illustrates how an initial treatment plan can be reevaluated and additional treatment options can be generated or considered during additional treatment planning.
[0060] Figure 2A presents a flow chart of an exemplary method for a tooth modeling system.
[0061] Figure 2B shows another exemplary method for adjusting a treatment process when the results deviate from the initial treatment plan.
[0062] Figure 3A shows an exemplary process for planning a treatment process in the creation of a model file.
[0063] Figures 3B to 3D show several views of a tooth to be digitally manipulated by means of movement widgets displayed on the tooth of interest.
[0064] Figure 4 presents an exemplary marking system when planning the treatment process.
[0065] Figure 5 shows a rolling or hanging ball method to detect the tooth boundary during treatment planning.
[0066] Figure 6A shows how the scroll or suspension ball accompanies the tooth pin.
[0067] Figure 6B shows how the trajectory path of the sphere can be used to find the margin lines between adjacent teeth.
[0068] Figure 6C shows how, once the margins are defined, the entire dental model can be sealed in two parts to detect a limit or geometry of the tooth.
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21/111 [0069] Figure 7 presents an exemplary mass spring model that can be used to model teeth and gums as an interconnected system.
[0070] Figure 8 presents an example of how treatment planning can be implemented in relation to the patient.
[0071] Figure 9 is a functional block diagram of a multiple tooth model system useful for implementing the tooth movement control techniques described here.
[0072] Figure 10 is a schematic diagram or
of blocks functional on one system for use in provision in management of movement tooth or Control of movement of tooth over two or tooth.[0073] A more objectsFigure 11A furniture, such aspresents a process
example for the manufacture of a dental appliance using a reticular structure.
[0074] Figure 11B presents an exemplary process for the manufacture of a dental appliance with a thickness of variant material using a reticular structure.
[0075] Figure 12A presents a perspective view of an example of a basic structure formed in a lower half and an upper half for a dental appliance using a reticular structure that can be used in a 3D printing process.
[0076] Figure 12B shows an exemplary view in detail of the openings in a reticular structure.
[0077] Figure 12C shows an exemplary final view of a lattice structure having several lattice layers.
[0078] Figure 12D shows a final view
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22/111 exemplary of a reticular structure having regions comprised only of the coating material.
[0079] Figure 12E presents a detailed perspective view of a reticular structure and coating having a characteristic, such as an extension formed from the surface.
[0080] Figure 12F presents a detailed perspective view of a reticular structure and coating having different regions with varying unit cell geometries.
[0081] Figure 12G presents a detailed perspective view of a reticular structure and coating having different regions formed with different thicknesses.
[0082] Figure 12H shows an exemplary final view of a reticular structure having regions with a coating on a single side.
[0083] Figure 121 shows a perspective view of an aligner having at least one additional component integrated.
[0084] Figure 12J shows an exemplary final view of a reticular structure, an articulation or other mobile mechanism integrated along the reticulum.
[0085] Figure 12K shows a perspective view of an aligner having one or more (internal) channels integrated.
[0086] Figure 13 presents a detailed perspective view of a part of an aligner having an area that is machined to have a part of relatively thicker material to accept an elastic.
[0087] Figures 14A and 14B illustrate a variation of a free-form dental appliance structure having a relatively rigid reticular structure and
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23/111 one or more features for use as a dental appliance or retainer.
[0088] Figure 14C shows a partial cross-sectional view of a suction feature manufactured to adhere to one or more teeth in particular.
[0089] THE Figure 14D features an seen in perspective of an part of aligner by having regions configured for facilitate chewing or speaking fur patient. [0090] THE Figure 14E features an seen in
perspective of a part of the aligner having different parts manufactured to have different areas of varying friction.
[0091] Figure 14F shows a perspective view of part of the aligner having a particulate coating.
[0092] Figures 15A to 15D show several views of examples of reticular structures suitable for the formation of dental appliances.
[0093] Figure 16 shows an exemplary 3D printed dental structure with a support positioned within the structure.
[0094] Figures 17A and 17B show lateral views in cross section of several realizations of a 3D printed dental structure having an internal and external layer.
[0095] Figure 18 shows another realization of a dental structure printed in 3D with a defined bag inside.
[0096] Figure 19 shows yet another realization with a sphere-like material positioned between two parts of the tooth.
[0097] Figure 20 shows an exemplary model having a slot to support metal wires itself.
[0098] Figure 21 shows a process
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24/111 copy to adjust the thickness of the 3D printed mouthpiece.
[0099] Figure 22 presents an exemplary process for determining the thickness of a mouthpiece based on physical simulation.
[00100] Figure 23 shows an exemplary process for the manufacture of a mouthpiece.
[00101] Figures 24 and 25 show side views of an exemplary process of defining a finishing line between opposite points in a digital model of the mouthpiece.
[00102] Figure 26 shows a top view of a mouthpiece formed with one or more slits to facilitate manufacturing.
[00103] Figure 27 shows a side view of a mouthpiece mounted on a manufacturing base.
[00104] Figure 28 shows a side view of the buccal appliance and some of the directions that the appliance can travel and / or be rotated to facilitate the finishing of the appliance.
[00105] Figure 29 shows a top view of a cutting device that can be used to finish the mouthpiece and some of the directions in which the cutting device can be articulated.
[00106] Figure 30 shows a top view of a mouthpiece and a cutting device for manufacturing.
[00107] Figure 31 shows a side view of a mouthpiece fixed to a base for processing.
[00108] Figure 32 shows an exemplary process for laser cutting a physical mold for the oral appliance.
[00109] Figure 33 shows a side view
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25/111 of a mouthpiece formed with a utensil cavity
to facilitate the articulation of the mouthpiece.[00110] Figure 34 features a View side from another device buccal having a region formed for to facilitate the removal of the device through a flow air or gas. [00111] The figure 35 features one process
to facilitate removal of the mouthpiece.
[00112] Figure 36 shows a side view of another mouthpiece having a cavity formed to facilitate its removal by means of a shed removal member.
[00113] Figure 37 shows an exemplary process to facilitate the removal of the oral appliance by means of the foot removal member.
DETAILED DESCRIPTION OF THE INVENTION [00114] The present invention will be described in relation to particular embodiments, but the invention is not limited to this, but only by the claims. Any reference signs in the claims should not be construed as limiting its scope.
[00115] As used herein, singular forms one, one, and o / a include referents both in singular and plural, unless the context clearly dictates otherwise.
[00116] The terms comprising, comprising and comprised of, as used herein, are synonymous with including, includes or containing, contains, and are inclusive or unlimited and do not exclude members, elements or additional method steps, not mentioned. The terms comprising, understanding and understood of, when referring to members, elements or method steps mentioned also include achievements consisting of said members,
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26/111 elements or steps of methods mentioned.
[00117] In addition, the terms first, second, third and the like, in the description and in the claims, are used to distinguish between similar elements and not necessarily to describe a sequential or chronological order, unless specified. It is to be understood that the terms thus used are substitutable under suitable circumstances and that the embodiments of the invention described herein are capable of operation in sequences other than those described and illustrated here.
[00118] The term about, as used here, when referring to a measurable value, as a parameter, an amount, a duration of time and the like, is intended to encompass variations of +/- 10% or less, preferably +/- 5% or less, more preferably +/- 1% or less, and still more preferably +/- 0.1% or less from and from the specified value, as long as these variations are suitable for carrying out the disclosed invention . It should be understood that the value to which the modifier refers, in itself, is also specifically and preferably revealed.
[00119] The mention of numerical variations by end points includes all numbers and fractions subsumed within the respective variations, as well as the mentioned end points.
[00120] All documents mentioned in this specification are hereby incorporated by
reference in their integrity.[00121] Unless defined from other way, all the terms used in revelation gives invention, including terms t technical and scientific, have O meaning according commonly understood by a technician at the subject in
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27/111 question to which this invention belongs. By way of further guidance, definitions for the terms used in the description are included to better understand the teaching of the present invention. The terms or definitions used herein are provided only to assist in understanding the invention.
[00122] Reference, throughout this specification, to an embodiment or embodiment means that a particular aspect, structure or feature described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases soft surface of gum or in the performance, in different places throughout this specification are not necessarily referring, all, to the same performance, but it can be. In addition, the particular aspects, structures or characteristics may be combined in any appropriate manner, as will be apparent to a person skilled in the art of this disclosure, in one or more embodiments. In addition, although some of the achievements described herein include some, but not other aspects included in other embodiments, combinations of aspects of different accomplishments are understood to be within the scope of the invention, and form different accomplishments, as will be understood by those skilled in the art. For example, in the claims that follow, any of the claimed embodiments can be used in any combination.
[00123] In the treatment of a patient to correct one or more conditions with his dentition, the steps of digitally scanning a patient's dentition, treatment planning and / or optionally manufacturing treatment devices, such as aligners to correct positioning of one or more teeth, can be performed directly at the service provider's office.
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28/111 [00124] As shown in the exemplary process of Figure IA, the step of scanning a patient's dentition 10 can be performed using several different processes, as described in further details here. With digital images resulting from a patient's dentition, treatment planning 18 to correct positioning, misalignment, malocclusion, etc. of any one or more teeth can be performed using any of the processes described herein. Conventional treatment planning typically creates an entire treatment plan, starting with the initial positioning of a patient's dentition and formulation of a treatment based on a gradual realignment of the dentition. This graduated realignment is then used to create a complete array of aligners, starting with an initial aligner and ending with a final aligner for use throughout the treatment process.
[00125] However, the treatment planning 18 and manufacturing process 20 described here can be carried out in a variable treatment path. That is, although the initial treatment planning 18 can be passed through the initial positioning of a patient's dentition, the step-by-step process for subsequent treatments is variable, so that the final treatment stage is not predetermined. On the contrary, dentition alignment is determined in intermediate stages in which the patient can (or may not) return to the service provider's office for reassessments and, possibly, new scans and aligners for one or more intermediate treatment steps. In this way, additional aligners or other treatment processes can be created during each visit to the service provider by the patient. Thus, the entire treatment process is created
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29/111 as treatment progresses, thus leading to treatment planning 18 and manufacturing process 20 as an iterative process rather than a complete predetermined treatment sequence at the beginning of treatment.
[00126] An example is shown in the flowchart of Figure 1B that illustrates how the initial treatment planning 30 can be carried out and one or more initial aligners can be manufactured for use by the patient. After the initial treatment, the patient can be evaluated 32 and additional treatment options 34 can be generated or considered during additional treatment planning. Based on evaluation 32, several treatment options can be considered and the patient re-evaluated 36, 38, for example, after a predetermined period of time. The assessment can be formed by the service provider based on the progress or lack of progress of moving the patient's tooth or teeth to a desired position. In addition, the patient can also collaborate with the service provider to provide their own assessments, thoughts, etc., so that the service provider can consider not only the physiological data, but also the collaboration provided by the patient.
[00127] Depending on which treatment option was targeted, additional treatment options 40, 46 can be considered and their corresponding result reassessed 42, 44, 48, 50 again, depending on which treatment option was targeted. Depending on the evaluation and, if necessary, the patient can again be provided with treatment options 52, 54, 56, 58 and the process can be continued at predetermined intervals until the desired result is achieved. Because the treatment process is not predetermined from the beginning to the end of the entire treatment and treatment options can be varied, aligners can be
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30/111 manufactured with only a short time. This also provides flexibility to the service provider to change the evolution in the middle of the treatment, without having a complete arrangement of unused prefabricated aligners.
[00128] Returning to Figure IA, the manufacturing process 20 itself can be carried out using different methods. In one example, the partially corrected patient's dentition model can be formed as a positive mold, for example, by means of a 3D printing mold 22 and corresponding aligner or aligners can be thermally formed 24 on the positive molds. In another example, the one or more aligners can be formed directly, for example, direct 3D printing 26. In any case, the resulting one or more aligners 28 can be formed for use by the patient.
[00129] DENTITION SCANNING [00130] Obtaining a digital model of a patient's dentition to facilitate treatment planning can be performed in several different ways. The patient can have his dentition scanned at another location and forwarded to the treatment provider, or his dentition can be scanned directly at the treatment provider's location. In any case, the patient's dentition can be scanned digitally by any number of suitable scanning devices. For example, the patient may have his dentition (including teeth, soft tissue, or both) scanned by an MRI scanner, X-ray machine, intraoral scanner, etc. The resulting scanned images can be saved or loaded into a computer system and used to generate a digital image of the teeth, which can be used for treatment planning to correct positioning, misalignment, malocclusion, etc. of any one or more teeth. In a way
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Alternatively, the patient's dentition can be fused to obtain an impression that can then be used to create a positive impression. The resulting positive mold reflecting the patient's dentition can then be scanned to obtain the corresponding digital image.
TREATMENT PLANNING [00131] The treatment planning process can be implemented after receiving and analyzing the scanned dental model of a patient's dentition. The scanned dental model can likewise be processed to allow the development of a treatment plan that can be readily implemented for the manufacture of one or more positioners for use in making sequential movement of the teeth.
[00132] Figure 2A shows an exemplary general tooth modeling process that can be used in treatment planning to correct malocclusions in a patient. The process presented may initially involve the acquisition of a patient's dental record 110 in the form, for example, of lower arch and / or upper arch CAD files, intraoral photographs, X-rays or 3D CT scans etc. The lower arch and / or upper arch CAD files can be created, for example, by several different methods, such as obtaining lower and upper impressions of a patient's dentition, X-rays, etc.
[00133] Once dental records are acquired, the ratio of the lower and upper jaws can be imported or calculated 112 for registration by one or more computing devices and a flexible dental anatomy model can be created automatically 114 by one or more processors located in the vicinity of where the patient is treated, for example, a dental office, or remotely from the patient's location. An
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32/111 Since the dental anatomy model was created digitally and confirmed to fit and the arch model can open and close as expected, one or more possible treatments can be created in real time, in patient's office 116 and the one or more treatment options can be presented and / or discussed with the patient in office 118 where simulations of treatment options can also be presented and / or discussed to possibly change the treatment plan as needed. Simulations of treatment options can be displayed to the patient using a variety of electronic display methods.
[00134] After discussing treatment options with the patient, the treatment plan (with any changes) can be used to generate manufacturing files for manufacturing machinery 120, for example, 3D printing machines, thermal forming, sintering laser etc. Because one or more of the resulting positioners can be manufactured locally, in close proximity to the patient (eg, dental office, clinic, nearby facility, etc.), the resulting one or more positioners for use by the patient can be manufactured locally, allowing the patient try one or more positioners 122 during the same visit.
[00135] This treatment plan may have particular advantages over conventional treatment plans and plans, including one or more of the following:
• exact treatment can be developed directly and discussed with the patient in real time;
• the service provider has complete control over treatment plan options that are easy to create;
• real gum modeling can be implemented;
• one or more positioners can be manufactured locally, allowing the patient to test during the same
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33/111 visit;
• easy to incorporate other treatment methods, for example, indirect bonding apparatus, rubber tapes, hooks, retainers etc. in combination with one or more positioners.
[0013 6] Even in the case where a treatment plan has been developed and implemented for a patient, as presented and described for Figure 2A, the actual progress of tooth movement (s) may not correspond to the treatment plan or real progress may start to deviate from the treatment plan. Due to this variability, not all positioners or aligners can be manufactured at the beginning of treatment, but positioners can instead be manufactured at pre-established stages for use by the patient until a subsequent visit to the service provider, for example, at each six weeks, in which a new set of positioners can be manufactured for subsequent treatments. Figure 2B shows an example of this treatment planning in stages in which the treatment plan can be adjusted during the actual treatment, according to any changes or deviations by the patient's progress. In addition, implementing a staged treatment planning process also allows the service provider to employ other devices or methods (for example, devices, wires, etc.) to correct malocclusions in addition to or in place of manufactured positioners.
[00137] As described above, the patient's dentition can be scanned or otherwise recorded to capture a three-dimensional (3D) 130 representation of a patient's dentition and an initial treatment plan can be determined 132 for the formation of a or more dental devices 134 to correct any malocclusions. To
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34/111 Instead of manufacturing dental appliances for the entire treatment process, a number of staged appliances can be initially manufactured for use by the patient, until their subsequent visit. The service provider can assess the progress of the patient's tooth movement on subsequent visits, according to treatment plan 136 as originally developed. In determining whether the patient's tooth movement progress differs from treatment plan 138, the service provider may compare the treatment plan with the actual movement of the patient's tooth (s) to determine whether they correlate. This correlation can be done in several ways, for example, visually by the service provider or the patient's dentition can be scanned again and the captured 3D representation of the treated dentition can be compared digitally in relation to the treatment plan.
[00138] If the system determines that the actual progress of tooth movement does not differ from the treatment plan, tooth movement can be continued, according to treatment plan 140, without change, and an additional number of positioners can be manufactured for use by the patient until the subsequent visit. As long as the next visit and subsequent visit proceed according to the original treatment plan, the additional set of positioners can be manufactured until treatment is completed and malocclusions corrected.
[00139] However, if during any of the assessments, the service provider determines that the actual movement of the tooth differs from the treatment plan, the service provider may be alerted to the deviation 142 by the system. The treatment plan can then be automatically adjusted by the system for the next set of dental devices or positioners 144 to correct
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35/111 deviations, so that the newly manufactured positioners provide a better fit to the patient's dentition and are responsive to the correction of deviations. On subsequent visits, tooth movement with the changed treatment plan can be evaluated 136 to determine whether tooth movement differs from the changed treatment plan 138 and if deviation is not detected, treatment can be continued, but if a deviation, the service provider may be alerted to the deviation and the treatment plan changed again to be adjusted accordingly. This process can be continued until the movement of the detected teeth appears to follow the treatment plan.
[00140] Due to the system being programmed to alert the service provider of any deviations for the teeth in particular, the service provider is able to determine if the patient is non-adherent to the use of the positioner and / or if there is any problematic movement of the teeth that the service provider can then signal to continue treatment or whether other devices or methods, for example, conventional appliances, can be used for particularly problematic teeth. The treatment plan (like any subsequent treatment plans) can be shared with third parties using any number of methods and / or devices.
[00141] When importing or calculating the relationship between the lower arch and upper arch 112, digital models of the lower arch and / or upper arch can be loaded 150, for example, on a computer, as shown in the flowchart of Figure 3. Additionally , as part of creating a dental anatomy model 114, the bite registration between the lower and upper jaws can be adjusted and mounted on a virtual articulator 152 and the user can then drag and drop the tooth ID to an area of interest 154
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36/111 to correct malocclusion. In digital modeling of the margin between the crown and gingiva, the process can assign regions that are designated as rigid and soft 156 with adjusted conditions where a region with a rigid designation cannot change its shape and a region with a soft designation is capable of being deformed with an included rigid region.
[00142] Additionally, any number of movement widgets can be defined in different regions or locations 158 to facilitate the movement and control of the regions. For example, the process may allow the definition of movement widgets: medium / distal, lingual / facial, vertical, etc. In addition, the user can be enabled to control the widgets and calculate a new model transformed 160 in the development of a treatment plan. Once the treatment plan has been completed, the plan can be exported, for example, to a model file accepted by 3D 162 printer, for use in the manufacture of one or more of the positioners or for the manufacture of molds for subsequent thermal formation.
[00143] These movement widgets can be view-based widgets that facilitate the manipulation of the model in the development of the treatment plan. When the model is displayed in a particular view, the manipulation widgets displayed can be programmed to allow manipulation of the model in the particular view that is displayed. For example, Figure 3B shows a lingual / facial view with the movement widget 164 displayed on the T tooth of interest to be moved for treatment planning. With the T tooth of interest displayed, for example, on a screen or monitor, the motion widget 164 can be displayed on or over the particular T tooth. The movement provided by widget 164 can move the digital model of the T tooth in several translational and / or rotating movements. THE
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37/111
Figure 3C shows how the T tooth presented in a vertical / apical view can have the 164 'movement widget displayed on the T tooth to digitally manipulate the Tea tooth. 3D Figure shows a medium / distal view of the T tooth with the 164' movement widget. 'displayed in a similar way for treatment planning.
[00144] Additionally and / or optionally, each tooth can be displayed in its natural color or, alternatively, colored, for example, yellow or red, to indicate to the service provider that a proposed corresponding movement is difficult or unlikely to be achieved by providing the service provider with guidance on finding alternative treatments.
[00145] In preparing the scanned image of a patient's dentition for treatment planning, the digital model can be initially marked. For example, Figure 4 shows an example of a marking system in which the scanned dentition model 170 can be seen. Several 172 markings, in this example, a total of 16 markings (for example, 1 to 16 or 17 to 32, depending on the arch), can be initially arranged along the 170 model, allowing the user to assign a mark to a focused tooth , for example, when dragging and dropping a mark on a particular tooth. In this example, while the mark is dragged, it can remain visible, but after being assigned to being dropped on a particular tooth, the tooth can change to indicate that it has been marked. For example, the tooth may have changed color to indicate that it is now marked, for example, red to indicate an unassigned tooth to white to indicate the tooth that is marked.
[00146] In facilitating treatment planning, movement widgets can be defined in digital model 158 and controlled 160 accordingly, as
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38/111 discussed above. As shown in Figure 4, an example of a movement widget is illustrated in which a central vertex 174, indicated with a circle, can be defined along the model 170. The related mesh of the selected vertex must be in the form of a single region connected to provide a way to read the list. The central vertex 174 is indicated as a center, while a second vertex 176 can be defined in relation to the central vertex 174, so that the first arm 178 defined between them can point directly out of the tooth surface in the lingual to buccal direction. A third vertex 180 can be defined in relation to the central vertex 174, so that the second arm 182 defined between the points along the center of the teeth in the middle to distal direction. The first arm 178 and second arm 182 need not be perpendicular to each other. The movement widget can only be applied to the teeth that are marked (and therefore the teeth that can be moved in the model) and can provide a way to read and orient the direction of the arms 178, 182 and their origin. The move widget can be hidden from view from the user when not in use.
[00147] Once the marked tooth and a small set of mesh are identified, a drop ball algorithm can be used to detect the gingival margin and the tooth margin. Figure 5 presents an exemplary process for digitally detecting and identifying a limit or geometry of the patient's scanned dentition tooth by simulating a scroll or suspension sphere 194 to detect the limit of tooth 190 and gum 192. Ball 194 can be simulated for rolling from a high energy state 196, for example, in the tooth crown, to a low resting state 198, for example, in the tooth bottom. As sphere 194 'rolls longitudinally, there is a protrusion 200 that points to the
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39/111 margin area between the tooth and gum, where the inflection changes. By looking at these areas and at the correct curvature changes, the margin line can be detected. This method can also detect occluded tooth margins and gum margins as well.
[00148] However, to detect the lateral margin between two adjacent teeth, the scroll ball algorithm can be used, as described, to follow the known margin lines of the teeth, but intermediate to the adjacent teeth, the limit of the teeth can be extrapolated. For example, Figure 6A shows an example in which the scroll ball 194 can be rolled to follow the outer line of adjacent teeth 212, 214. The intermediate region 218 of the teeth may be generally inaccessible to ball 194, but the ball will naturally follow pin 216 of the teeth. With that, the extrapolated path path 220, 222 that the scroll ball 194 will follow between teeth 212, 214 can be used to find the margin lines between adjacent teeth 212, 214, although sphere 194 cannot access region 218 intermediate, as shown in Figure 6B.
[00149] As shown in Figure 6C, once the margins are defined on the model, the entire dental model can be separated into two parts: a rigid crown surface and a soft gingival surface. In one embodiment, the rigid surface 224, 226 can be considered a rigid surface that moves in an integral part and maintains its shape during movement. The soft surface 228, 230 can be attached to the rigid surface 224, 226 and can deform based on the movements of the rigid surface 224, 226. This movement does not change the general topological structure of the dental model, therefore, the model finished by default is waterproof , which fits
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40/111 to the requirement of the 3D printer.
[00150] This diverts from the traditional separate model to the individual tooth model, which requires the models to be finished and then filled (hole filling) to make it waterproof. Due to the complexity of a scanned tooth geometry, this finish and filling of the hole is a very complex process.
[00151] Figure 7 shows an exemplary mass spring model 240 that can be applied to the dental model in determining tooth movement. In general, it is desirable, in some configurations, to synchronize the movements and operation of individual tooth models in order to have few tooth models operating in a choreographed manner, as dictated by a treatment professional. Having this choreographed movement is not typically possible through manual control, in which the tooth models move randomly and independently. The present control method and / or system are ideal for use in the movement of different tooth models and to provide synchronized tooth movement. This method can be non-collective to avoid any collisions between the teeth and, also, to avoid the appearance of merely random movements, at least in some applications. On the contrary, it is desirable that the tooth models react with each other in a safe manner to environmental conditions, such as changes in bone structure and soft tissue during tooth movement in a group of choreographed tooth models.
[00152] The mass spring model 240 can be restricted to be directly attached to a rigid surface and the model 240 can be stretched or compressed. Any number of algorithms can be used to calculate its shape, for example, mass spring model, in an implementation of
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41/111 mass spring model 240, two nodes can be modeled as mass points connected by a parallel spring and damper circuit. In this approach, the body is modeled as a set of point masses (nodes) connected by ideal light elastic springs, fulfilling some variant of Hooke's law. These nodes can derive from the edges of a two-dimensional polygonal mesh representation of the object's surface, or from a three-dimensional network of nodes and edges that model the internal structure of the object (or even a one-dimensional system of connections, if, for example, a cable or head wire is being simulated). Additional springs between the nodes can be added, or the spring force law modified to achieve desired effects. Having the restricted dental model as a 240 mass spring model helps to synchronize the movement and operation of individual tooth models to have few tooth models operating in a choreographed manner.
[00153] The application of Newton's second law to point masses including the forces applied by the springs and any external forces (due to contact, gravity etc.) provides a system of differential equations for the movement of the nodes, which is solved by standard numerical schemes for solving common differential equations. The granting of a three-dimensional mass spring reticulum is generally carried out using freeform deformation, in which the granted mass is incorporated into the reticulum and distorted to conform to the shape of the lattice involved. Assuming that all point masses are equal to zero, it is possible to obtain the stretched mesh method that aims to solve several engineering problems in relation to the behavior of the elastic mesh.
[00154] Another way to calculate model 240 is used finite element analysis (FEA) models in which
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42/111 the soft parts of the model are separated into smaller FEA elements, for example, tetrahedron or cubic elements, and some of the element surfaces can be affixed to the rigid parts, such as the so-called boundary condition in FEA analysis, while the soft parts (gingiva parts) can be attributed to several material properties, such as Young's Module, compatible with the gingiva parts. While the rigid parts are moving, the boundary condition can change and, therefore, all elements based on these connections to their neighboring elements can form large matrices. When solving these matrices, each individual element shape and locations can be calculated to provide a calculated gum strain during treatment.
[00155] In one embodiment, the body can be modeled as a continuous three-dimensional elastic by breaking it into a larger number of solid elements that fit together and for which a model of the material can be solved to determine the stresses and pressures in each element. The elements are typically in tetrahedron, the nodes being the vertices of the tetrahedron (tetrahedralize a three-dimensional region connected by a polygonal mesh in tetrahedron, similar to how a two-dimensional polygon can be triangulated in triangles). The pressure (which measures the local deformation of the points of the material from its resting state) can be quantified by the pressure tensor. The stress (which measures the local area forces per unit in all directions acting on the material) can be quantified by the Cauchy stress tensor. Given the current local pressure, local tension can be computed using the generalized form of Hooke's law. The equation of motion of the element nodes can be obtained by integrating the stress field over each element and relating this, through the second
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43/111 Newton's law, at node accelerations.
[00156] An energy minimization method can be used, which is motivated by the principles of variation and surface physics, which dictate that a restricted surface will take the form that minimizes the total deformation energy (analogous to a soap bubble) . Expressing the energy of a surface in terms of its local deformation (the energy is due to a combination of stretching and bending), the local force on the surface is given by differentiating the energy in relation to the position, producing an equation of motion that can be solved in standard ways.
[00157] The shape combination can be used where forces or penalty restrictions are applied to the model to direct it to its original shape (for example, the material behaves as if it had shape memory). To preserve the dynamics, the rotation of the body must be properly estimated, for example, by means of polar decomposition. To get closer to finite element simulation, shape matching can be applied to three-dimensional lattices and multiple shape matching constraints mixed together.
[00158] Deformation can also be manipulated by a traditional physical rigid body mechanism, modeling the movement of the soft body using a network of multiple rigid bodies connected by constraints, and using, for example, matrix palette skinning to generate a mesh of surface to grant. This is the approach used for deformable objects in the Havok Destruction.
[00159] The processes, computer-readable media and systems described here can be performed on various types of hardware, such as computer systems 250, as shown in Figure 8. These computer systems 250 can include a bus or other mechanism
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44/111 communication to communicate information and a processor coupled to the bus to process information. A computer system 250 may have a main memory, such as a random access memory or other dynamic storage device, coupled to the bus. Main memory can be used to store instructions and temporary variables. The computer system 250 may also include a read-only memory or other static storage device attached to the bus to store static information and instructions.
[00160] The computer system 250 can also be attached to a screen, such as a CRT or LCD monitor 254. Input devices 256 can also be attached to the computer system 250. These input devices 256 can include a mouse, a trackball , cursor direction keys, etc. for use by user 258. Computer systems 250 described herein may include, but are not limited to, computer 252, screen 254, 3D scanner / printer 260, and / or input devices 256. Each computer system 250 can be implemented using one or more physical computers or computer systems or parts of them. The instructions executed by the computer system 250 can also be read in a computer-readable medium. The computer-readable medium can be a CD, DVD, optical or magnetic disk, laser disk, transmitting wave, or any other medium that is readable by the computer system 250. In some embodiments, wired circuits can be used in place of or in combination with software instructions executed by the processor.
[00161] As will be apparent, the aspects and attributes of the specific achievements disclosed here can be combined in different ways to form additional achievements, all of which are within the scope of this
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45/111 revelation.
[00162] Conditional language used here, as, among others, may, could, could, for example and the like, unless specifically stated otherwise, or otherwise understood within the context, as used, is, in general, designed to convey that certain achievements include, while other achievements do not include certain aspects, elements and / or states. Thus, this conditional language is not, in general, intended to imply that aspects, elements and / or states are, in any case, necessary for one or more achievements or that one or more achievements necessarily include logic to decide with or without insertion or stimulation of the author, if these aspects, elements and / or states are included or must be realized in any particular realization.
[00163] Any process descriptions, elements or blocks in the flowcharts described here and / or depicted in the attached figures should be understood as possibly representing modules, segments or pieces of code that include one or more executable instructions to implement specific logic functions or steps in the process. Alternative implementations are included within the scope of the achievements described here, in which elements or functions can be excluded, performed outside the order presented or discussed, including, substantially, simultaneously or in reverse order, depending on the functionality involved, as will be understood by the technicians on the subject.
[00164] All the methods and processes described here can be carried out and completely automatic by means of software code modules executed by one or more general purpose computers or processors, such as the computer systems described here. The modules
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46/111 code can be stored on any type of computer-readable medium, or other computer storage device. Some or all of the methods can alternatively be performed on specialized computer hardware.
[00165] It should be emphasized that many variations and modifications can be made to the achievements described here, whose elements must be understood as being, among others, acceptable examples. All such modifications and variations are intended to be included here, within the scope of this disclosure, and are protected by the following claims.
[00166] In addition to the processes for modeling individual teeth and tissues, there are control methods and additional systems (or systems of multiple teeth models incorporating these control methods / systems) for use in controlling a group of tooth models, numbering if 1 to 32. That is, the method treats groups of teeth as a group (for example, as a group of birds that travel collectively) in planning tooth movements for treatments to correct malocclusions.
[00167] Briefly, the control method uses supervisory control based on hierarchy with multicast techniques along with adaptive logic, including integrated or local control modules provided in each tooth model to adjust tooth movement paths to safely avoid collisions with based on communication with nearby tooth models. The result of the described control of multiple tooth models in an oral cavity is the collective behavior, in which the tooth models appear to move in a synchronized manner with movements that are not completely independent or completely centrally controlled.
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47/111 [00168] The control method in planning a treatment can be implemented in a 310 system in general having several components including a tooth movement management module 312, a crash management module 314, and a tooth management module 316 to control the movement of tooth models. These components or aspects of the control method / system 310 communicate with a computer system 318 and are described below and as shown in Figure 9.
[00169] Figure 9 illustrates a tooth / computer controller or tooth movement control system (SCMD) 310 that can be used to control tooth movement in a safe and reproducible manner. System 310 includes tooth movement management module 312 that communicates with computer system 318 (which includes one or more processors) in which the digital tooth models of a patient's teeth 320 reside. As shown, digital tooth models in the 318 computer system are configured for communication between tooth or tooth models and, as explained here, this intercom allows teeth 320 to safely change their path to correct malocclusions when determining whether teeth in particular 322, 324 are on conflicting movement paths to avoid collisions, while generally remaining on a predefined tooth movement path.
[00170] During the execution moments, the tooth movement manager 312 is programmed to send commands to the computer system 318 to monitor and maintain the performance and quality and, also, to monitor the safety of the teeth to be moved. The tooth movement manager 312 is further programmed to load tooth movement requirements into the computer system 318 during downtimes, for example, moments of non
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48/111 execution.
[00171] A second module, the collision manager module 314, can be programmed to interact with the computer system 318 to handle collisions between the teeth to be moved. The collision manager 314 can be programmed to perform the following logic: (a) calculate a sphere of influence on each tooth model, for example, determine a proximity distance between each tooth model to trigger a collision event and if a tooth model enters this sphere of influence over a specific tooth model, a collision event is triggered; (b) determine, by the nearest neighbor algorithm, if a possible conflicting route will occur; and (c) present to the operator, in a user interface provided on the 318 computer system (for example, by means of a monitor device), that a possible path conflict will occur between any two teeth. The collision module 314 can store the tooth movement paths in memory, for example, within the computer system 318.
[00172] Another module includes a tooth management module 316 that is programmed to monitor the expected state and the real state of each of the teeth 320. For example, module 316 can compare a current position or travel speed, for example, tooth 324, with its expected state that can be defined by a tooth movement path or a choreographed and / or synchronized time movement of tooth models, as with an animation of the treatment. Based on this monitoring, the tooth management module 316 can make adjustments, as using the following priorities: location (for example, position of one tooth model in relation to another tooth or teeth model); environment (for example, adjustment of bone or similar conditions); security (for example,
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49/111 returning the tooth model to a safe location or operational mode if the tooth model or other tooth models are not operating as expected); presentation performance (for example, position adjustment, speed, or other operational parameters to meet presentation needs); tooth status; and operator persuasion / performance needs.
[00173] As discussed above, the tooth manager module 316, collision module 314, and tooth movement manager 312 are configured to work together to provide collective type control. In use, tooth model intercommunications allow operational data to flow or propagate hierarchically between each tooth model instead of having centralized / isolated tooth movement control. In other words, the tooth management module 316 provides a level of centralized control or central logic that acts to control the movement of the tooth / teeth models, as in providing tooth movement paths provided by the tooth movement management module 312 and / or making adjustments in real time based on a comparison of the expected state and real state (or for security reasons), as provided by the collision manager module 314. With respect to communication between tooth models, it may be useful to note the following : (a) some units can be designated as master nodes that speak to tooth manager 316; and (b) the master nodes can operate to send calculated information or commands of movement between teeth to the remaining tooth models.
[00174] The movement of individual tooth models and control of models are not based on collective in part, as tooth models based on collective can
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50/111 collide with each other or have an inherent lack of security. The 310 system is designed to prevent random movements since digital tooth models are subject to movement like a flock having synchronized movements between the individual tooth models. However, model communication between teeth, as processed and generated by the local control modules allows each tooth model to react safely to environmental conditions, such as changing direction and the presence / movement of neighboring teeth, such as movement paths of the tooth. crossed teeth is allowed in the 310 system. In other words, the integrated logic acts to control the movement of the teeth, in order to avoid collisions, while trying to keep, in general, in the path of movement of the tooth.
[00175] Figure 10 illustrates a general system (or a tooth movement management control system) 330, in general, for use in the management or control of tooth models to provide synchronized tooth movement when simulating flock movement. of teeth to correct malocclusions. As shown, a treatment plan for moving one or more 332 teeth to correct malocclusions can be initially developed. The system can include components used to perform offline activity and used to perform online activity. Off-line activity may include projecting or selecting a choreographed treatment or movement concept for a plurality of tooth models to achieve a particular effect or perform a task (s). The concept of tooth movement (for example, digital data stored in memory or the like) can be processed with a 318 computer system or other device.
[00176] Each tooth to be used can be modeled as a particle to simulate movement of one or more teeth as a bunch of teeth 334 (as a bunch of
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51/111 birds), as described here. Accordingly, each digitized tooth model can be configured by the computer system 318 to define a three-dimensional space, like a three-dimensional sphere with a predefined diameter, on top of each tooth model. This three-dimensional sphere can be used to define a safety wrap for the tooth model or launched object to reduce the risk of a collision between the individual tooth models. For example, each tooth model can be created and choreographed by the 318 system to avoid collisions with each other and where two or more tooth models are prohibited having their safety sheaths crossed or overlapping as the tooth models move along their tooth movement paths.
[00177] The tooth movement plan created for multiple tooth models is then exported to the memory of the 318 computer system or other devices for processing with this treatment illustration typically including one file for each tooth model. Each of these files is processed to generate real world coordinates for each tooth model to be achieved over time during an animation or performance of a choreographed task (s) to illustrate the movement of teeth 336, for example, on a screen, to the service provider and / or patient. This processing creates individual tooth movement plans for each tooth model, and that processing or generation of the tooth movement plans can include processing the modeled animation based on specific logistical requirements. For example, these requirements can be modified as needed, for example, it is the dental space of the same size and shape as in the simulation and, if not, modification can be useful for changing or adjusting real world coordinates for one or more of the models tooth.
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52/111 [00178] Once the treatment plan has been approved 338, the treatment plan can be used to manufacture one or more dental appliances or positioners using, for example, three-dimensional printing 340, locally, at the treatment planning location .
[00179] In planning, the simulation of the movement of the individual tooth models as a bunch of 334 teeth for operation of a treatment plan, the tooth models can be manipulated using the SCMD 310 described here. Logistical requirements may also include adjusting a movement of the actual tooth to the location and adding safe or familiar points, where each tooth can be positioned securely, such as at the beginning and end of a treatment process or when a safety cancellation is transmitted (e.g., stop). A treatment planning management component may have considered a component that translates to the central treatment plan controller commands in which tooth actions are sent to the tooth management component via scripts (for example, data files), messages real-time computer and / or hardware triggers.
[00180] The tooth movement planes are provided to the SCMD 310, as described above, and the system also includes several tooth models presented in the form of teeth, in this example. The teeth can be organized into groups or sets with a set presented to include, for example, two molars, a set including a molar, and a set including cusp teeth, among others. These sets can act or function together, at least for a part of the animation or movement path of the tooth, to perform a particular display or task.
[00181] In other cases, all teeth can be considered part of a broad set that moves
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53/111 as a flock or, otherwise, their movements are synchronized in time and / or choreographed by planes of tooth movement. A tooth in the group can communicate with its close or neighboring teeth, in order to determine its presence, to determine its proximity, and when necessary, to process the tooth's plane of movement, determine the position of the neighbor and other environmental data to modify its plane of movement of the tooth to avoid collision and / or communicate with the nearby tooth to instruct it to move or otherwise change its plane of movement of the tooth / movement to avoid collision.
[00182] During pre-movement of the tooth, an operator uses the SCMD to load a plane of movement of the tooth for each tooth model. During a sequence of tooth movements, the SCMD and its tooth management module 316 act to execute the tooth movement plane previously loaded in the tooth model. During dental treatment, SCMD actively monitors safety and a service provider can initiate an SCMD user action. More typically, however, SCMD monitors the operation of all tooth models in the flock by processing telemetry data provided by each tooth model provided by each tooth model. In some embodiments, the tooth management module 316 has software / logic that compares the actual state of each tooth model in relation to the state expected at that particular moment for the tooth model, according to the currently approved tooth movement plan .
[00183] After the go or start signal is emitted by the tooth manager / SCMD module upon the entry of an operator, the SCMD together with the local control software / hardware in each tooth model works to carry out the safety plan safely. tooth movement / presentation
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54/111 preloaded. As discussed above, the control method and system combine centralized control (for example, to allow manual override for safety or other reasons during a task based on tooth presentation / movement) with intelligent tooth models to provide more effectively flock type movement of tooth models. In other words, tooth models can each be awarded a particular tooth movement plane on which they will work over time (for example, during an animation period), while trying to respond to the unexpected presence of another model tooth inside or near its safety window (or safe operational wrapper that surrounds each tooth model, such as a sphere, for example, 1 to 3 mm or similar, where no other tooth model will typically travel to avoid collisions) .
[00184] During operations, SCMD is used to trigger each tooth model to start its stored tooth movement plan, starting from an initial starting point, for example, each tooth model can be placed at different starting. In some cases, after a tooth model will receive it, each tooth model uses its local control module (or other software / programming) to try to follow the tooth movement plan, but without time restrictions. In other words, the plane of movement of the tooth can define a series of points or paths for the tooth model. In these embodiments, the tooth model is controlled in a relatively fluid manner and is not linked to the performance of specified movements in a certain amount of time, for example, the plane of movement of the tooth does not require the tooth model to be in a particular location at a particular time after the signal will be received, thus allowing flexibility in planning.
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55/111 [00185] In some implementations, the tooth movement plane can be constructed assuming that each tooth model travels at a pre-established and constant tooth movement speed. This tooth movement speed can be adjusted independently for each tooth model or it can be the same (or within a relatively small variation) for each tooth model. In other cases, however, the local control module can be adapted to adjust the speed of movement of the tooth to suit the conditions in the patient's mouth. The bone stiffness can be determined in the tooth model with the local control module and / or by means of optical sensors to detect the actual movement of the tooth (instead of the planned movement) that can be provided to the SCMD for each model tooth. In some cases, flock control is preferred, so that each tooth model has its speed adjusted in a common way, for example, each tooth model performs at similar tooth movement speeds while moving in a similar direction, so to appear to have synchronized and not random movement.
[00186] In some realization, each tooth model can act independently to try to continue to follow its own tooth movement plan. Each plane of movement of the tooth may differ in that each tooth model starts at a different or familiar starting point and moves to its first crossing point. To this end, each tooth model is equipped, as necessary, to determine its present three-dimensional position at its current height, above the line. The local control module uses your position data to determine or modify, if necessary, your current direction or position to continue moving towards the next via point on your tooth movement plane. This may involve changing
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56/111 of its course and also its angle to reach the desired height at the crossing point.
[00187] An operator can take steps to manually override a particular among the many tooth models to provide better control of that tooth model. For example, the SCMD 310's tooth control module can operate to compare an expected position of the tooth model with its actual position (provided by means of a rear channel in its telemetry or other data). An alert can be provided in a graphical user interface (GUI) that the tooth model is trending out of course or is out of an accepted tolerance to reach its next via point.
[00188] For example, the GUI can present tooth models operating and positioned properly in a first color (for example, green) and tooth models that are off course or out of position in a safe amount in a second color (for example, example, yellow) and tooth models outside a safe casing in a third color (for example, red). Red / unsafe tooth models can be manipulated automatically or manually to cause them to enter a safe operating mode (for example, return to the point of residence). Yellow tooth models that are operating outside the desired conditions can be operated manually to try to help them return to their tooth movement path, such as changing the speed manually, direction, angle of attack, or the like to bring the model faster tooth to a desired crossing point. After manual operations are completed, control can be returned from the SCMD to the local control module for local control of the tooth model based on the plane of movement of the tooth stored in its memory. The SCMD can be configured to assess issues
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57/111 collision and execute commands to avoid collision to preserve the quality of presentation (for example, tooth movement performance) in degrading oral conditions.
[00189] In other embodiments, a local tooth control module can operate to adjust the plane of tooth movement during tooth movement to better respond to environmental conditions (such as toothache or temporary gum discomfort, at least temporarily off course). For example, a plane of movement of the tooth can provide a relative time for a starting moment (when it is signaled by the file SCMD to the tooth models) to reach each of its paths in the plane of movement of the tooth. An achievement can evoke a tooth model to determine a distance to a next tooth model and its current estimated time of arrival. If the arrival time is not within a window over a pre-established / target arrival time, the local control module can act to increase the tooth movement speed of the tooth model, such as increasing the rotation rate of a tooth. Likewise, if the tooth model is moving very quickly, the location of the tooth model, the control module can act to slow the movement of the tooth. In this way, the movement of the tooth models can remain better synchronized to provide flock control.
[00190] In other cases, however, the local tooth control module or other tooth models act to determine whether a crossing point has been reached within a predefined time window with the plane of movement of the tooth defining moments to be at each crossing point in relation to a departure / go time. If not (for example, the tooth model has not reached a crossing point at the moment
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11/111
X plus a permissible delay), the local control module can act to modify the plane of movement of the tooth by directing the tooth model to jump to the next crossing point and move directly to the crossing point inside the mouth.
[00191] For example, a tooth movement plane can include paths A to Z. If a local control module determines that a predefined time window for the crossing point C has not been reached, the local control module can skip or remove the crossing point D from the plane of movement of the tooth and cause the tooth model to obtain a direction / stroke (for example, a straight line or another predefined path) to the crossing point E. Thus, the movement speed of the tooth is maintained (for example, all tooth models are moved at the same speed) while allowing the tooth model to reach if they are back in their plane of tooth movement (for example, by defining a set of paths to pass through or close within a predefined period of time that can correspond to a time to perform a presentation / exhibition or perform a task with teeth).
[00192] Regarding security and monitoring of operations, each tooth model can store a definition of a demarcated area that defines an external perimeter (and an internal area in some cases) or the limit of a geographical area. The local tooth model control module compares the current position determined for the tooth model during tooth movement and compares that position to the marked area. If this limit is crossed (or is being approached, as within a pre-established distance from the demarcated area), the local control module can act to promptly return the tooth model back within the limits of the demarcated area. In other cases, the tooth model
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59/111 can be changed to a safe operating mode and this can cause the tooth model to return to a home position.
[00193] Also, regarding safe tooth model operations, some tooth movement achievements, control may involve configuring tooth models to have tooth-to-tooth model (or tooth-to-tooth) communications to avoid collisions without counting on SCMD intervention. Each tooth model can use its local control module to operate continuously to detect when another tooth model is within a predefined distance from the tooth model, such as within a 1 to 3 mm sphere or the like. The first tooth model to detect this condition (or both tooth models if linked) generates a collision alert message and transmits that message to the nearby / molten tooth model to change its current course or position for moving the first tooth space of tooth models. For example, the tooth model that receives this collision alert message can store an evasive action in its memory and initiate that action (a fixed movement, such as a right or left angle from a predefined angle). Evasion can be carried out for a pre-established period of time, and then the tooth model can return to following its tooth movement plan (for example, recalculating a course to the next crossing point of its new current location or similar ).
[00194] In another example, the local tooth model control module monitors the current orientation of the tooth model and if the orientation is outside an acceptable range (for example, the tip or rotation exceeds 320 degrees or similar for a tooth ) or if the body movement is too much, the local control module can also act to insert the tooth model in an operational mode
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60/111 insurance (before or after trying to fix the operational problem).
[00195] Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure was made by way of example only, and that several changes in the combination and arrangement of parts can be restored by those skilled in the art, without deviating from the spirit and scope of the invention, as hereinafter claimed.
[00196] As will be apparent, the aspects and attributes of the specific achievements disclosed here can be combined in different ways, to form additional
achievements, all which They are in of scope gives present revelation.[00197] MANUFACTURE ONE OR MORE ALIGNERS[00198] 0 system described here is related The manufacturing of dental appliances such as retainers and
aligners, using three-dimensional (3D) printing processes. The apparatus can be formed to have hollow shapes with complex geometries using tiny cells known as reticular structures. Topology optimization can be used to assist in the efficient mixing of solid reticular structures with smooth transition material volume. The performance of the lattice can be studied under tension, compression, shear, flexion, torsion, and fatigue time.
[00199] Reticular free-form structures are provided here, which adjust at least part of the surface, for example, external contour of a body part. Specifically, the described embodiments may use reticular freeform structures for forming or manufacturing appliances that are designed for placement or positioning on the external surfaces of a dentition.
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61/111 patient to correct one or more malocclusions. The free-form structure is at least partially manufactured by additive manufacturing techniques and uses a basic structure comprised of a reticular structure. The reticular structure can guarantee and / or contribute to a free-form structure having a defined stiffness and the reticular structure can also guarantee ideal coverage over the dentition by a coating material that can be provided in the reticular structure. The reticular structure is at least partially covered by, impregnated in and / or surrounded by the coating material. In addition, the achievements of the reticular structure can contribute to the transparency of the structure.
[00200] The term reticular freeform structure, as used herein, refers to a structure having an irregular or asymmetrical shape or contour, more particularly fitting at least part of the contour of one or more parts of the body. Thus, in particular embodiments, the freeform structure can be a freeform surface. A free-form surface refers to a (essentially) two-dimensional shape contained in a three-dimensional geometric space. In fact, as detailed here, this surface can be considered as essentially two-dimensional in that it has limited thickness, but it can, independently, to some degree, have a varying thickness. Since it comprises a reticular structure rigidly adjusted to mimic a particular shape, it forms a three-dimensional structure.
[00201] Typically, the free-form structure or surface is characterized by an absence of corresponding radial dimensions, different from regular surfaces, such as flat, cylindrical and conical surfaces. Freeform surfaces are known to the person skilled in the art and widely
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62/111 used in engineering design disciplines. Typically, non-uniform rational B-spline mathematics (NURBS) is used to describe surface shapes; however, there are other methods, such as Gorden surfaces or Coons surfaces. The shape of the freeform surfaces is characterized and defined not in terms of polygonal equations, but by their poles, degree and number of fragments (segments with grooved curves). Freeform surfaces can also be defined as triangulated surfaces, where triangles are used to approximate 3D surfaces. Triangulated surfaces are used in Standard Triangulation Language (STL) files that are known to the CAD design technician. Free-form structures adjust to the surface of a part of the body, as a result of the presence of a rigid basic structure itself, which provides structures with their free-form characteristics.
[00202] The term rigid, when referring to the reticular structure and / or free-form structures including it here refers to a structure that has a limited degree of flexibility, more particularly, the rigidity ensures that the structure forms and retains a shape predefined in a three-dimensional space before, during and after use and that this general shape is mechanically and / or physically resistant to the pressure applied to it. In particular embodiments, the structure is not foldable on itself, without substantially losing its mechanical integrity, manually or mechanically. Despite the general stiffness of the shape of the predicted structures, the specific stiffness of the structures can be determined by the structure and / or material of the reticular structure. In fact, it is predicted that reticular structures and / or free-form structures, while maintaining their general shape in a three-dimensional space, may have some (local) flexibility for manipulation. As will be
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63/111 detailed here, (local) variations can be followed by the nature of the reticular structure pattern, the thickness of the reticular structure and the nature of the material. Furthermore, as will be detailed below, when the freeform structures provided herein comprise separate parts (for example, non-continuous lattice structures) that are interconnected (for example, by hinges or areas of facing material), the stiffness of the form may be limited to each of the areas comprising a reticular structure.
[00203] In general, the methods provided for here are for dental appliance manufacturing processes in which the manufacturing process includes the design of a appliance used on the teeth to be covered by a free-form structure, mold making, and provision of (one or more) reticular structures in it and provision of the coating material in the mold, so as to form the structure in a free form. Free-form structures are patient-specific, that is, they are made to fit specifically in the anatomy or dentition of a particular patient, for example, animal or human. Figure 11A, in general, presents a general exemplary method for the manufacture of a dental appliance by capturing a 3D representation of a body part of an individual 410. In this example, this may involve capturing the 3D representation of surfaces, for example example, external contours, of a patient's dentition to correct one or more malocclusions. To this end, the individual can be scanned using a 3D scanner, for example, a hand held laser scanner, and the collected data can then be used to build a digital, three-dimensional model of the individual's body part. Alternatively, patient-specific images can be provided by a technician or
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64/111 scan the individual or part of it. These images can then be used as or converted to a three-dimensional representation of the individual, or part of him. Additional steps in which the scanned image is manipulated and, for example, cleaned, can be envisaged.
[00204] With the captured 3D representation, a free-form structure generally understood of a reticular structure that combines at least part of the surface of the body part, for example, the dentition, can be generated 412. The design of a free-form structure based on said three-dimensional representation of said body part, so that the structure is essentially complementary to at least part of said body part and comprises or consists of a reticular structure. In the reticular structure, one or more types and / or sizes of unit cells can be selected, depending on the individual's shape, the necessary stiffness of the free-form structure, etc. Different reticular structures can be drawn within the structure freely to fit different locations on the body part. The different reticular structures can be provided, for example, with a joint or other movable mechanism, so that they can be connected and / or can be digitally mixed together or connected by bundles in the basic structure to grant a single part.
[00205] This step can also include steps necessary to design the reticular structure, including, for example, defining surfaces in the positive impression of the mask that may need different properties, different cell sizes and / or openings, generating the cells with the necessary geometry and standardizing them as needed on the defined surfaces to cover said surfaces, and combining cell patterns
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65/111 separated into a single solid part. It should be noted that the requirements of the reticular structure will be clear to a person skilled in the art while designing the reticular structure. The technician, therefore, will use data obtained from his own experience as well as data from numerical modeling systems, such as FE and / or CFD models.
[00206] The reticular free-form structure can then, in fact, be manufactured, for example, by additive manufacturing methods 414. In certain embodiments, this may include the provision of a coating material over the basic structure, in which the The coating material is preferably a polymer. These different steps do not have to be carried out in the same location or by the same institutions. In fact, typically, free-form structure design, fabrication and coating can be carried out in different locations by different developers. In addition, it is envisaged that additional steps can be taken between the steps mentioned above. In coating or impregnating the basic free-form structure, the reticular structure can be impregnated with a certain material, such as a polymer, thereby generating the free-form structure. This may include steps such as adding polymeric material or other material to the dental appliance, curing the material that impregnates the reticular structure and disassembling the dental appliance.
[00207] After manufacturing the free-form structure, the structure can go through several post-process steps, including, for example, cleaning and finalizing the free-form structure. In addition, other applications for forming a rigid free-form structure, as described herein, may also include applications for, among others, therapeutic, cosmetic and protective applications.
[00208] In a particular application the use of
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66/111 free-form structures described here can be used in the care and treatment of damaged skin surfaces, such as burn wounds. In additional realizations, the use of the free-form structures described here can be used in the care, protection and treatment of undamaged skin surfaces. According to additional particular embodiments, the use of a freeform structure as described herein can be used for cosmetic purposes. In additional embodiments, the use of a free-form structure as described herein can be used for the release of skin care agents. In other particular embodiments, the structure further comprises one or more therapeutic compositions that can be incorporated into the coating material. Still, in additional embodiments, the use of the structures described here can be used as prosthetic devices, for example, to replace a body part, in which the free-form structures can be made to be identical to the absent body part.
[00209] Figure 11B presents another exemplary general process for the manufacture of a dental appliance having a reticular structure similar to that presented above in Figure 11A. In this example, once the 3D representation has been captured 410, the amount of force required to move a tooth or teeth can be determined and finite element analysis can be used to determine an appropriate thickness of alignment material required for the associated force 410A to move. one tooth or teeth in particular. In this way, one or more mouthpieces can be manufactured with varying material thicknesses in which regions that may not need a lot of strength are manufactured to have a relatively thinner region while regions of the appliance that may need a greater amount of force to move the tooth or teeth
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67/111 can be manufactured to have relatively thicker regions of material to create a mouthpiece having directional resistance (Differential Force), depending on the particular forces necessary to correct particular malocclusions. Simulations can be performed on the modeled dentition (or aligners) to confirm the manipulation of the stress point for the different thicknesses of the 410B aligner.
[00210] Then, as previously described, the free-form structure comprised, in general, a reticular structure that combines at least part of the surface of the body part, for example, dentition, 412 can be generated and the shape structure free reticular can then be actually manufactured, for example, by 414 additive manufacturing methods. However, the one or more mouthpiece can be manufactured to have regions of relatively thick and / or fine-tuned material to accommodate directional resistance (Differential Strength ) of the mouthpiece, as described in further details below.
[00211] Figure 12 shows a perspective view of an exemplary mouthpiece 420 having two parts 422 (for the upper and lower dentition). As shown, the mouthpiece 420 generally includes a reticular structure 424 that can be used in a process for manufacturing the final mouthpiece. In the process, the reticular structure 424 can first be 3D printed in a shape that approximates the oral appliance to be manufactured to correct malocclusion and the reticular structure can be positioned inside a dental appliance 426, 426 '. Then, the dental appliance 426, 426 'containing the formed reticular structure 424 can be filled with the impregnating material 428, for example, polymer or other materials described herein. After
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68/111 establishment of the impregnating material 428, the halves of the dental appliance 426, 426 'are removed to produce the coated oral appliance 420.
[00212] Although the entire lattice structure 424 can be coated or impregnated with the impregnating material 428, only parts of lattice structure 424 can be coated or particular surfaces of lattice 424 can be coated while leaving other parts exposed. Variations of these achievements are described in further detail below in relation to the mouthpiece 420 shown in Figure 12.
[00213] As can be seen, an approach for progressive aligners printed in 3D of varying and / or increasing thickness has certain advantages. For example, the rate of further increase in thickness may not be dependent on the standard thicknesses of the plastic sheet available as an industrial commodity. An ideal thickness could be established for the 3D printing process. For example, instead of being limited to, for example, 0.040, 0.060 and 0.080 in. Thickness sequence, a service provider, such as an orthodontist, could choose a sequence, such as 0.040, 0.053 and 0.066 in., For an adult patient whose teeth are known to reposition more slowly compared to a rapidly growing adolescent patient.
[00214] Given the concept that an aligner formed from the thinner material generates, in general, less corrective forces than an aligner configured in an identical way formed from thicker material, it follows that an aligner could be printed in 3D, so that be thicker in areas where bigger forces are needed and thinner in areas where lighter forces are needed. Having the latitude to produce aligners with
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69/111 a first standard thickness and then areas of varying thickness could be favorably explored to help service providers address many difficult day-to-day challenges. For example, any malocclusion will consist of teeth that are further away from their desired end positions than other teeth. In addition, some teeth are smaller than others and the size of the tooth corresponds to the limit of absolute force necessary to start tooth movement. Other teeth may appear more resistant due to many factors, including the proximity of the root of the tooth to the limits between the cortical and alveolar bone support. Still, other teeth are simply more rigid to rotate in a corrective, angular, or straight way than others. In addition, other teeth and groups of teeth may need to be moved bodily as quickly as possible for comparatively wide ranges to close open spaces. At least, for these reasons, the option of customizing aligner thickness and therefore strength levels on regions containing larger teeth or teeth that are far from their desired destinations, or the more resistant teeth allows selected teeth to receive forces larger than small teeth positioned almost ideally.
[00215] The reticular free-form structure for dental appliances can be, at least partially, manufactured by additive manufacturing (AM). More particularly, at least the basic structure can be manufactured by additive fabrication using the reticular structure. In general, AM can include a group of techniques used to manufacture a tangible model of an object using typically computer-aided design (CAD) 3D data of the object. A variety of AM techniques are available for use, for example, stereolithography, selective laser sintering, fused deposition modeling, techniques
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70/111 based on film etc. Selective laser sintering uses high-powered laser or other focused heat source to sinter or weld small particles of plastic, metal, or ceramic powders into a mass that represents the 3D object to be formed. Fused deposition modeling and related techniques make use of a temporary transition from a solid material to a liquid state, commonly due to heating. The material is guided by an extrusion nozzle in a controlled manner and deposited in the required location, as described, among others, in US Patent No. 5,141,680, which is incorporated herein by reference in its entirety and for any purpose. Film-based techniques fix coatings to another by using, for example, glue or photo polymerization or other techniques, and then cutting the object from these coatings polymerizes the object. This technique is described in US Patent No. 5,192,539, which is incorporated herein by reference in its entirety and for any purpose.
[00216] Typically, AM techniques start from a digital representation of the 3D object to be formed. In general, the digital representation is sliced into a series of cross-sectional layers that can be superimposed to form the object as a whole. The AM device uses this data to build the object layer by layer. The cross-sectional data that represents the layer data
of the object 3D can to be generated using a system in computer and software in drawing and assisted manufacturing per computer (CAD / CAM).[00217] A structure basic understanding The
reticular structure can therefore be made of any material that is compatible with additive manufacturing and that is capable of providing sufficient rigidity to the rigid shape of the regions comprising the reticular structure in the structure of
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71/111 free form or the free form structure as a whole. Suitable materials include, but are not limited to, for example, polyurethane, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), PC-ABS, polyamide, polyamide with additives such as glass or metal particles, methyl methacrylate-acrylonitrile-butadiene-styrene copolymer etc. .
[00218] The reticular structure itself can be comprised of a rigid structure that has an open frame, for example, of 3D printed lattices. Reticular structures can contain a plurality of reticular cells, for example, tens, thousands, hundreds of thousands, etc. reticulum cells. Once the 3D dentition model is provided, the process can generate STL files to print the reticular version of the 3D model and create support structures, when necessary. The system identifies where material is needed in an appliance, and where it is not needed, before placing and optimizing the trusses.
[00219] The system can optimize dental trusses in two stages. First, it applies a topology optimization allowing more porous materials with intermediate densities to exist. Second, the porous areas are transformed into explicit lattice structures with varying material volume. In the second phase, the dimensions of the reticle cells are optimized. The result is a structure with solid parts plus zones of lattices with varying volumes of material. The system balances the relationship between material density and part performance, for example, in relation to the stiffness to volume ratio, which can impact design choices made earlier in the product development process. Porosity can be especially important as a functional requirement for biomedical implants. Zones of
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72/111 reticle could be important to the successful development of products where more than mere rigidity is needed. The system can consider curving behavior, thermal performance, dynamic characteristics, and other aspects, all of which can be optimized. The user can manipulate the material density based on the result of an optimization process, comparing stronger versus weaker designs, or solid versus empty truss. The designer first defines the objective, then performs optimization analysis to inform the design.
[00220] Although 3D printing can be used, trusses can also be made of strips, bars, beams, bundles or similar, which are in contact, crossing or overlapping in a regular pattern. Strips, bars, beams, bundles or the like have a straight shape, but they can also have a curved shape. The lattice is not necessarily made of longitudinal or similar bundles, and can, for example, consist of interconnected spheres, pyramids etc. among others.
[00221] The reticular structure is typically a frame that contains a regular repetition pattern, as shown in Figure 12A, in which the pattern can be defined by a given unit cell. A unit cell is the simplest repeating unit in the pattern. Thus, the lattice structure 424 is defined by a plurality of unit cells. The shape of the unit cell may depend on the necessary stiffness and may, for example, be triclinic, monoclinic, orthorhombic, tetragonal, rhombohedral, hexagonal or cubic. Typically, the unit cells of the structures
reticular have a volume what varies in, e.g. 1 to 8000 mm ³ , or preferably of 8 The 337 5 mm ³ , or more preferably in 64 The 3375 mm ³ , or much preferably of 64 The 1728 mm ³ . 0 size of cell
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73/111 unitary can determine, along with other factors, such as material choice and unit cell geometry, the inflexibility (rigidity) and transparency of the free-form structure. Larger unit cells, in general, decrease stiffness and increase transparency, while smaller unit cells typically increase stiffness and decrease transparency. Local variations in unit cell geometry and / or unit cell size may occur. Therefore, lattice 424 may comprise one or more repeated unit cells and one or more unique unit cells. In order to guarantee the stability of the reticular structure 424, the strips, bars, beams, bundles or the like may have a thickness or diameter of, for example, 0.1 mm or more. In particular embodiments, strips, bars, beams, bundles or the like may preferably have a thickness or diameter of, for example, 0.2 mm, 0.4 mm, 0.6 mm, 0.8 mm, 1 mm , 1.5 mm, 2 mm, 3 mm, 5 mm or more. The main function of the reticular structure 424 is to guarantee a certain stiffness of the free-form structure. The reticular structure 424 can additionally enhance or guarantee transparency, since it is an open frame. The lattice structure 424 can be considered, preferably, a lattice structure having the shape and / or appearance of, for example, a network or grid, although other embodiments can be used.
[00222] The stiffness of the reticular structure depends on factors, such as the density of the structure, which depends on the geometry of the unit cell, the dimensions of the unit cell and the dimensions of the strips, bars, beams, beams etc. frame 432. Another factor is the distance, S, between the strips and the like, or in other words, the dimensions of the openings in the reticular structure, as shown in the exemplary view in detail in Figure 12B. In fact, the structure
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74/111 reticular is an open frame and therefore comprises openings 434. In particular embodiments, the size of the aperture S of the reticular structure is between, for example, 1 and 20 mm, between 2 and 15 mm, or between 4 and 15 mm. In preferred embodiments, the opening size is between, for example, 4 and 12 mm. The size of the openings may be equal to or less than the size of unit cell 434, while, in other embodiments, the openings may be uniform in size or arbitrary in size. Yet, in another alternative, regions other than treiiça may have openings that are uniform in size, but that are different from other regions.
[00223] In particular embodiments, the free-form structures may comprise a lattice structure having one or more interconnected lattice layers, as shown in the final exemplary view of Figure 12C. For example, the lattice structure can comprise one, two, three or more lattice layers 438, wherein the lattice comprises different at least partially overlapping and / or interconnected layers 436, 436 ', 436' 'within the lattice. The degree of stiffness provided by the reticular structure can increase with the number of reticulated layers provided therein. In additional particular embodiments, the freeform structures may comprise more than one lattice structure. The examples presented are merely illustrative of the different achievements.
[00224] For certain applications, the reticular structure can also comprise one or more holes with a size larger than the openings or unit cells, as described here above. In addition or alternatively, the reticular structure may not extend over the entire shape of the structure freely, so that the openings in the structure or regions for manipulation, for example
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75/111 example, flaps or ribs, and / or regions of unsupported lining material are formed. An example of this application is a face mask, in which holes are provided in the location of the eyes, mouth and / or holes in the nose. Typically, these latter holes are also not filled by the coating material.
[00225] Similarly, in particular embodiments, the size of the openings that are impregnated in and / or surrounded by the junction material can vary between, for example, 1 and 20 mm. The holes in the reticular structure (corresponding to holes in the free-form structure), as described herein, will also typically have a size that is larger than the unit cell. Likewise, in particular embodiments, the unit cell size varies between, for example, 1 and 20 mm.
[00226] According to particular embodiments, as shown in the final view of Figure 12D, the predicted freeform structure may contain regions 433 comprised only of coating material 431. This may be of interest in areas where extreme flexibility of the structure free form is desired.
[00227] In particular embodiments, the predicted freeform structure may comprise a basic structure that contains, in addition to a reticular structure, one or more limited regions that do not contain a reticular structure, but are uniform surfaces, as shown in the perspective view detailed in Figure 12E. Typically, these 435 form extensions of the reticular structure have a symmetrical shape (for example, rectangular, semicircular etc.). These regions, however, typically encompass less than, for example, 50%, or more particularly less than, for example, 30%, or very particularly less than, for example, 20% of the complete basic structure. Typically, they are used as
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76/111 areas for manipulation (manual tabs) of the structure and / or for the placement of display structures (clips, elastic cords, etc.). In particular embodiments, the basic structure can essentially be comprised of only one reticular structure.
[00228] It may be advantageous that the dental appliance structure has certain regions with a different stiffness (as in molar teeth to provide added strength). This can be achieved by providing a lattice structure with locally varying unit cell geometries, varying dimensions and / or varying densities and / or varying unit cell thicknesses of the lattice structure (by increasing the number of lattice layers), as shown in the view in exemplary detailed perspective of Figure 12F. Likewise, in particular embodiments, the lattice structure is provided with varying unit cell geometries, varying unit cell dimensions, varying lattice thicknesses and / or varying densities 437, 439. Additionally or alternatively, as described herein, the thickness of the coating material can also be varied, as shown in Figure 12G. Thus, in particular embodiments, the freeform structure has a varying thickness with a first thickness region 441 and a second thickness region 443. In additional particular embodiments, the freeform structures may have regions with a different stiffness, while retaining the same volume and external dimensions.
[00229] In particular realizations of free-form structures, the basic structure or the reticular structure can be covered, in part, with a coating material that is different from the material used for the manufacture of the reticular structure. In achievements
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77/111 particular, the reticular structure is at least partially incorporated into or surrounded by (and, optionally, impregnated with) coating material, as shown in the final detail example of Figure 12H. In additional embodiments, the coating material is provided on one or both surfaces of the 436 lattice structure. In particular embodiments, only certain surface regions of the basic structure and / or the lattice structure in the freeform structure are provided with a material of coating, while parts can be exposed 445. In particular embodiments, at least one surface of the basic structure and / or reticular structure can be coated 431 by at least 50%, more particularly, at least 80%. In additional embodiments, all regions of the basic structure having a reticular structure are completely coated, on at least one side, with the coating material. In additional particular embodiments, the basic structure is completely incorporated with the coating material, with the exception of the flaps provided for handling.
[00230] In additional embodiments, the free-form structure comprises, in addition to a coated reticular structure, regions of coating material not supported by a basic structure and / or a reticular structure.
[00231] Likewise, in particular embodiments, the free-form structure can comprise at least two materials with a different texture or composition. In other embodiments, the freeform structure may comprise a composite structure, for example, a structure that is composed of up to at least two different compositions and / or materials.
[00232] The coating material (s) can be a polymeric material, a ceramic material and / or a
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78/111 metal. In particular embodiments, the coating material (s) is a polymeric material. Suitable polymers include, but are not limited to, silicones, a natural or synthetic rubber or latex, polyvinylchlorhydrate, polyethylene, polypropylene, polyurethanes, polystyrene, polyamides, polyesters, polyepoxides, aramids, polyethylene terephthalate, polymethylmethacrylate, vinyl acetate and ethylene. In particular embodiments, the polymeric material comprises silicone, polyurethane, polyepoxide, polyamides, or mixtures thereof.
[00233] In particular embodiments, free-form structures comprise more than one coating material or combinations of different coating materials.
[00234] In specific embodiments, the coating material is a silicone. Silicones are typically inert, which facilitates free-form cleaning of the structure.
[00235] In particular embodiments, the coating material is an optically transparent polymeric material. The term optically transparent, as used here, means that a layer of this material with a thickness of 5 mm can be seen through based on unaided visual inspection. Preferably, this layer has the property of transmitting at least 70% of the visible incident light (electromagnetic radiation with a wavelength between 400 and 760 nm) without diffusing it. Visible light transmission and, therefore, transparency, can be measured using a UV-Vis Spectrophotometer, as known to the technician in the subject. Transparent materials are especially useful when the freeform structure is used for wound care (see more) . Polymers can be derived from a type of
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79/111 monomer, oligomer or prepolymer and, optionally, other additives, or can be derived from a mixture of monomers, oligomers, prepolymer and, optionally, other additives. Optional additives can comprise an insufflation agent and / or one or more compounds capable of generating an insufflation agent. Blowing agents are typically used to produce a foam.
[00236] Likewise, in particular embodiments, the coating material (s) is (are) present in the free-form structure in the form of a foam, preferably a solid foam. Thus, in particular embodiments, the reticular structure is covered with a solid foam. Foam materials have certain advantages over solid materials: foam materials have a lower density, need less material, and have better insulating properties than solid materials. Solid foams are also excellent materials for absorbing impact energy and are therefore especially useful for the manufacture of free-form structures that are protective elements (see additionally). The solid foam may comprise a polymeric material, a ceramic material or a metal. Preferably, the solid foam comprises one or more polymeric materials.
[00237] Foams can be structured open cell foams (also known as cross-linked foams) or closed cell foams. Structured open cell foams contain pores that are connected together and form an interconnected network that is relatively soft. Closed cell foams have no interconnected pores and are, in general, denser and stronger than open cell structured foams. In particular embodiments, the foam is an integral skin foam, also known as self-skin foam, for example, a type of foam with a skin of
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80/111 high density and a low density center.
[00238] Thus, in particular embodiments, free-form structures may comprise a basic structure that includes a reticular structure that is at least partially covered by a polymeric or other material, as described herein. For some applications, the thickness of the coating layer and the uniformity of the coating layer thickness are not essential. However, for certain applications, it may be useful to provide a layer of coating material with a layer thickness adjusted at one or more locations of the freeform structure, for example, to increase the flexibility of adjusting the freeform structure on the part of the body.
[00239] The basic structure of the free-form structures provided here can be made as a single rigid free-form part that does not need a separate aligner or other elements. Regardless, it is envisaged that the free-form structures can still be provided with additional components 447, such as sensors, strips or other aspects to maintain the structure in position on the body, or any other characteristic that may be of interest in the context of the use of structures and integrated within or along the structure, as shown in Figure 121. Several examples of sensors that can be integrated are described in further detail here.
[00240] In certain embodiments, the free-form structure comprises a single rigid reticular structure (optionally, comprising different interconnected layers of cross-linked material). However, these structures generally allow only limited flexibility, which can cause discomfort to a person or animal that uses the structure freely. An increase in flexibility can be obtained if the structure is free-form
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81/111 comprise two or more separate rigid reticular structures that can move in relation to each other. These two or more reticular structures are then encased in a material as described above, so that the resulting free-form structure is still made or provided as a single part. The rigidity of the shape of the free-form structure is guaranteed locally by each of the reticular structures, while additional flexibility during placement is guaranteed by the fact that there is (limited) movement of the reticular structures in relation to each other. In fact, in these embodiments, the coating material and / or a more limited lattice structure will typically ensure that the lattice structures remain attached to each other.
[00241] In particular embodiments, the reticular structures are partially or completely overlapping. However, in particular embodiments, the different reticular structures are not overlapping. In additional particular embodiments, the reticular structures are mobilely connected to each other, for example, by means of a joint or other mobile mechanism 449, 449 ', as shown in the final detailed view of Figure 12J. In particular projects, the connection is guaranteed by the lattice material. In additional particular embodiments, the reticular structures can be interconnected by one or more bundles that form extensions of the reticular structures. In additional embodiments, the reticular structures are held together in the structure freely by the lining material. An example of such a free-form structure is a face mask with a jaw structure that is mobile in relation to the rest of the mask. Likewise, in particular embodiments, the reticular structure comprises at least two structures
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82/111 separate lattices, mobilely connected to each other, thus the lattice structures are integrated into the structure freely, as shown.
[00242] The free-form structure can be used to treat wounds, as described here. For optimal healing, the free-form structure provides uniform contact and / or pressure at the wound site or specific locations at the wound site. The reticular structure makes it simple to incorporate pressure sensors into the structure freely, in accordance with the present invention. The sensors can be external sensors, but they can also be internal sensors. In fact, the reticular structure can be designed, so that it allows the assembly of several sensors in precise locations, as described above, before impregnating and / or involving the reticular structure with a polymer or other material.
[00243] Additionally or alternatively, the free-form structure can comprise one or more other sensors, as described above in Figure 121, such as a temperature sensor, a humidity sensor, an optical sensor, a voltage meter, a accelerometer, gyroscope, GPS sensor, step contactor etc. Accelerometers, gyroscopes, GPS sensors and / or step counter can, for example, be used as an activity monitor. Temperature sensor (s), humidity sensor (s), tension meter (s) and / or optical sensor (s) can be used to monitor the healing process during wound treatment. Specifically, the optical sensor (s) can be used to determine the structure of collagen fiber, as explained in the North American Patent Application 2011/0015591, which is hereby incorporated by reference in its integrity and for any purpose.
[00244] Likewise, in achievements
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83/111 particulars, the free-form structure still comprises one or more external and / or internal sensors. In specific embodiments, the free-form structure comprises one or more internal sensors. In certain embodiments, the free-form structure comprises one or more pressure and / or temperature sensors.
[00245] The person skilled in the art will understand that, in addition to the sensor (s), also sources and / or associated energy means for transmitting signals from the sensor (s) to a receiving device can be incorporated into the structure freely, such as cabling, radio transmitters, infrared transmitters, and the like.
[00246] In particular embodiments, at least one sensor can comprise technology of micro-electronic mechanical systems (MEMS), for example, technology that integrates mechanical systems and electronic micro-components. Sensors based on MEMS technology are also referred to as MEMS sensors and these sensors are small and light, and consume relatively little energy. Non-limiting examples of suitable MEMS sensors are the STTS751 temperature sensor and the LIS302DL STMicroelectronics accelerometer.
[00247] As shown in Figure 12K, the reticular structure also allows the provision of the free-form structure with one or more (internal) channels 451. These channels can be used to release treatment agents to the skin, tissue or teeth of base. The channels can also be used for the circulation of fluids, such as heating or cooling fluids.
[00248] A philosophy of orthodontic treatment is known as Differential Force invoked for the corrective forces directed at the teeth to be strictly personalized, according to the ideal force level requirement of each tooth. The Differential Strength approach was
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84/111 supported by hardware based on calibrated springs designed to provide only these ideal levels of required force. By transmitting the concepts of the Differential Strength approach to the principles of aligner manufacturing, it can be seen that CNC-machined aligners that have carefully controlled variable thickness can achieve Differential Strength objectives from tooth to tooth. The compartments around the teeth can have wall thicknesses established at the CAD / CAM level by a technician based on the needs of each tooth. A 3D printed aligner can have an unlimited series of regions, each with a unique offset thickness between its internal and external surfaces.
[00249] Before installing these devices, a service provider can assess the progress of a case in the middle of treatment, for example and in particular, notice problem areas in which the desired tooth response is delayed or cases in which the teeth in particular, they are not moving obstinately in response to treatment forces. The 3D printed structure can include a group of small devices that are intended to be strategically positioned and printed in 3D with an aligner structure. These devices are called auxiliary aligners. Figure 13 is a detailed view of part of an aligner 440 showing a 3D printed area 442 that is machined, allowing thicker material to accept a 444 elastic. Other 3D printed geometries of interest would be fractions or pressure points, creating openings / windows in the aligner for a combination treatment, for example, forming hooks in the aligner for elastic tapes, among others. Alignment aids can be installed in these locations to amplify and focus corrective forces from the aligner to
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85/111 intensify the correction. For example, an auxiliary known as a tack can be installed after a hole of a predetermined diameter is drilled through a wall of a compartment containing an aligner's tooth. The diameter of the hole may be slightly smaller than the diameter of a part of the nail stem that can be printed directly on the aligner. These progressive sized studs and other auxiliary devices are commercially available to orthodontists who use them to increase and extend the tooth position correction forces of the aligners.
[00250] Protuberances can also be used and serve to focus the energy stored locally in the region of the aligner structure adjacent to a protuberance. The protruding inward protrusion causing the aligner material to flex outward in a region distant from the tooth surface. Configured in this way, protuberances collect the stored energy from a wider area and force that energy to the tooth at the most advantageous point mechanically, thus focusing corrective forces more efficiently. An aspect of elastic hook 450 can be printed in 3D directly on an area, otherwise, without aspects of an aligner structure, as shown in the side views of Figures 14A and 14B. Elastic hooks can also be used as an anchor point for orthodontic elastics that provide tensile forces between the sectioned parts of an aligner (or an aligner and other structures flexibly attached to the teeth) as needed during treatment.
[00251] In addition to hook aspects 450, other aspects, such as suction characteristics 452, can be manufactured to adhere to one or more teeth in particular T, as shown in the partial cross-sectional view
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86/111 of Figure 14C. In this way, the aligner can exert a directed force 454, concentrated on one or more teeth in particular.
[00252] In yet another embodiment, as shown in the perspective view of Figure 14D, the occlusal surfaces of the aligner can be manufactured to have defined areas to facilitate chewing or speaking by the patient. These aspects may include occlusal regions that are tuned, made on a flattened surface 456, or made with any number of projections 458 to facilitate chewing.
[00253] Additionally, different parts of the aligners can be manufactured to have different areas of varying friction 460, as shown in the perspective view of Figure 14E. These varying areas can be formed, for example, along the edges to prevent wear of the aligner material.
[00254] Additional displays can be formed on 3D printed dental appliances, such as particulate coatings. The particulate coating 462 can be formed on the tooth engaging surface of the 3D printed lattice apparatus in any convenient manner, for example, melting, sintering, etc., as shown in the perspective view of Figure 14F. The particles that make up the coating can be of any convenient shape, including a spherical shape or an irregular shape, and can be constructed of metal (including alloys), ceramic, polymer, or a mixture of materials. The particulate coating adhered to the engagement surface of the tooth may be in the form of different particles that are spaced apart on the surface, or in the form of a layer or multiple layers of particles joined together to produce an interconnected pore network. The coating
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87/111 particulate provides a porous interface to which a fluid binding resin can readily flow and penetrate. By curing the resin in solid form, mechanical interlocking is achieved between the cured resin and the particulate coating. Under some circumstances, chemical bonding beyond this mechanical bonding can be achieved, for example, by using polycarboxylated cement or glass ionomer with stainless steel and other metallic substrates and with ceramic substrates.
[00255] For a coating of integrally joined particles that make up a porous structure having a plurality of interconnected pores extending through it, the particles are commonly meshed around -100, and preferably a mixture of particles of varying particle sizes restricted to one of three size variations, for example, -100 + 325 mesh (about 50 to about 200 microns), -325 + 500 mesh (about 20 to about 50 microns), and - 500 (less than about 20 microns). The size of the particles in the porous structure determines the pore size of the pores between the particles. Smaller pores are preferred for fluid resin bonding agents while larger pores are preferred for more viscous cementitious bonding materials. Particle size selection is also used to control the porosity of the coating within the range of about 10 to about 50% by volume.
[00256] Adequate structural strength is required for the substrate and coating compound, so that any fracture of the joint between the appliance and the tooth occurs in the resin and not in the coating. To achieve this condition, the structural strength of the coating, the interface between the coating and the substrate and the substrate itself is at least 8 MPa.
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88/111 [00257] Figures 15A to 15D show explored views of alternative reticular structures that can be used in any of the embodiments described here. Reticular structures have open faces and are layered and can also be considered as their or more interconnected lattice layers or as structures comprising only one layer or more than two layers.
[00258] Figure 15A shows a first and second perspective view of the lattice structure 470 having a triangular cell pattern and an example of the structure 470 reconfigured in an alternative or compressed configuration 470 '. Figure 15B shows a first and second perspective view of lattice structure 472 having a polygonal cell pattern and an example of structure 472 reconfigured in an alternative or compressed configuration 472 '. Figure 15C shows a first and second perspective view of lattice structure 474 having a diamond cell pattern and an example of structure 474 reconfigured in an alternative or compressed configuration 474 '. Figure 15D shows a perspective view of the lattice structure 476 having a diamond cell pattern attached.
[00259] During the 3D printing process, the formed oral device may need to be supported by an intermediate structure given the complex shapes being built. These intermediate structures can be used temporarily and then removed, separated or otherwise disengaged from the oral appliance being formed.
[00260] Figure 16 shows a side view in cross section of an exemplary 3D printed dental appliance 510 with a temporary support structure 514 positioned inside the appliance 510. Typically, the appliance
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89/111 dental 510 is designed to stay in a patient's mouth for more than 518 hours a day for approximately one month. In addition to durability, the protection of the dental appliance 510 is desirably thin, typically having a thickness of about 0.5 mm. To be able to print in 3D, this protection or dental part to cover the teeth or tooth, the structure of Figure 16 can use the internal support structure 514 to support or structurally support the apparatus 510 formed on the support structure 514. Due to the occlusal surface 512 of the mouthpiece 510 may have a complex (or raised) anatomy, the interface surface 516 of the support structure 514 can be formed to reflect the occlusal surface 512, so that the occlusal surface 512 formed on the surface interface 516 during the manufacturing process sufficiently supports the mouthpiece 510.
[002 61] Once the formation of the apparatus 510 has been completed, the support structure 514 can be readily removed from the opening 518 defined by the apparatus 510. Thus, in one embodiment, the width of the support structure 514 may be similar to the opening 518 of apparatus 510 to allow removal of support 514 of apparatus 510. Apparatus 510 may be manufactured from a number of different types of polymers, for example, silicone, polyurethane, polyepoxide, polyamides, or mixtures thereof, etc., and the structure of support 514 can be manufactured from the same material, similar or different than that of the apparatus 510. The manufacture of the support structure 514 of a material different from the material of the apparatus 510 can facilitate the separation and removal of the support structure 514 of the apparatus 510, when finished.
[00262] In addition to having the support structure 514 positioned directly below the device 510 during
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90/111 manufacturing, other embodiments may include a support structure formed as one or more layers, as shown in partial side views in cross section of Figures 17A and 17B. Figure 17A shows an embodiment of a mouthpiece 520 during manufacture in which an inner central layer 522 can be formed (for example, by 3D printing) of a first material configured and deformed to follow the contours of the dentition. With the inner core layer 522 manufactured, an inner layer of the apparatus 524 can be printed on an inner surface of the inner core layer 522 and an outer layer of the apparatus 526 can be printed on an outer surface of the inner core layer 522. The inner core layer 522 can thus be formed to be slightly oversized in relation to the dentition to allow the manufacture of the inner layer of the apparatus 524 to be dimensioned. The inner layer of the apparatus 524 and the outer layer of the apparatus 526 can be printed on the inner core layer 522 sequentially or simultaneously to form the desired buccal apparatus 520. Subsequently, the inner core layer 522 can be fused, washed or otherwise dissolved , for example, by means of chemical compounds, leaving the completed mouthpiece 520 with the inner layer of the apparatus 524 and the outer layer of the apparatus 526 intact.
[00263] In another embodiment, Figure 17B shows a side view in cross section of an arrangement in which the mouthpiece 528 can be manufactured by an appliance layer 530 formed between an inner central layer 532 and an outer central layer 534. The layer internal central 532 can be formed to be slightly oversized in relation to the dentition to allow fabrication of the layer of the apparatus 530 to size. Once the device layer 530 was manufactured, while supporting
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91/111 through the inner core layer 532 and outer core layer 534, the inner core layer 532 and outer core layer 534 can be removed or otherwise dissolved, leaving the device layer 530.
[00264] Still, in another embodiment, the oral appliance can be manufactured with several characteristics, such as projections, protrusions or other ways to provide additional flexibility in the treatment of the patient. Figure 18 shows a side cross-sectional view of an example of a printed mouthpiece 540 having a pocket or cavity 542 formed along a side of the device, for example, to receive a fixture, such as an elastic band, which can be placed in the pocket or cavity 542. In this example, the support structure can include an aspect or projection 544 that causes the corresponding pocket or cavity 542 to protrude from the mouthpiece 540, as shown. Certain features can be printed in 3D for future assembly to provide additional treatment options and improve the effectiveness of the mouthpiece. In other embodiments, the support structure can be formed without any additional aspects, but the feature or projection 544 can be adhered to or otherwise attached to selected regions of the support structure to selectively form the corresponding pocket or cavity 542 on the mouthpiece 540. The feature or projection can be optionally designed, for example, to allow non-isotropic friction in a direction that helps the device to grasp the teeth better and move to their designated position.
[00265] Still, in another embodiment, characteristics or projections can, on the contrary, be incorporated into the buccal apparatus to transmit additional forces or facilitate movement of the teeth. An example is
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92/111 shown in the top view of Figure 19 illustrating a 550 projection (for example, a polymeric or metallic sphere) positioned by a mouthpiece (not shown for clarity) between two adjacent teeth 554, 556. Projection 550 can be manufactured as part of the buccal appliance that extends from the appliance and in contact with specific regions of a tooth or teeth, for example, to facilitate a separation movement between adjacent teeth 554, 556. Although a single projection 550 is presented , this projection or multiple projections can be used inside the mouthpiece.
[00266] In addition to the projections, the mouthpiece 560 can also define several channels, grooves or characteristics that support the use of additional devices. An exemplary mouthpiece 560 is shown in the top view of Figure 20 positioned on the teeth 562 of an individual and, furthermore, having slits 564, 566 defined within the mouthpiece 560 to support wires 568 inside. The mouthpiece 560 can be configured and printed with slots 564, 566 to receive, for example, wires, hooks, rubber bands etc., to supplement the corrective forces transmitted by the mouthpiece 560 to correct malocclusions as well as to intensify the resistance of the material and prevent loosening of the material, for example, in cases of arcade expansion. The wire 568 is shown anchored within the slits 564, 566 of the mouthpiece 560 for illustrative purposes, but alternative variations for slot positioning or incorporating other features or elements can also be used.
[00267] In another realization, due to the precise gingival modeling, the protection of the oral apparatus can be extended or thick to cover the gingival areas without hurting patients. These extended areas can reinforce the
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93/111 protection, for example, plastic, especially at times when shrunk plastic protection may not be able to provide the necessary strength.
[00268] Figure 21 shows an exemplary process for adjusting the thickness of the 3D printed mouthpiece. With the individual's dentition scanned and electronically converted, the 570 upper and lower arch models can be loaded into the memory of a computer system with a programmable processor. The bite register can be adjusted and the resulting digital model can be mounted on a virtual articulator 572. The system can be programmed to generate an initial protection model having a predetermined thickness 574 in which the thicker the parts of the mouthpiece, it provides a relatively stronger region. The service provider can incorporate aspect, such as projections 550 shown above in Figure 19 and / or even incorporate additional aspects, such as slits 564, 566 or any other aspects to the model of the mouthpiece. The system can then be programmed to activate an articulator to perform a simulated bite 576 between the upper and lower arch models to calculate any overlap between the upper and lower arch protection 578. Any resulting stresses in the mouthpiece protection model can also be determined.
[00269] The system can then remove any overlap when finishing protective material 580 on the model and any isolated islands or peninsular pieces can then be removed as well 582. The resulting 3D model can then be exported to a 3D printer 584 for the manufacture of the dental appliance or protection.
[00270] Figure 22 shows another exemplary process for determining the thickness of an oral appliance based on physical simulations. In this process, the model
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94/111 digital of the lower and upper arches can be loaded 590 to the memory of a computer system, as above. The new desired configuration for the arch and / or dentition can be inserted into the system which can calculate the necessary movements to occur in the tooth or teeth 592. The system can then generate an analytical model for an initial form of protection 594. The system can also run an analytical model to optimize forms of protection, including thicknesses and possible auxiliary components or parts that may be needed or desired 596. The analytical 3D model can be further optimized for better patient comfort and minimizing the cost of resin 598 and the The result can then be provided with a 3D printer 600 for the manufacture of the mouthpiece or protection.
[00271] In general, the pressure formed in the plastic protection that forms conventional oral appliances has intrinsic disadvantages. Ideally, the plastic shield has a relatively thin layer (for example, thinner than other regions of the appliance) in regions of the appliance that contacts the occlusal areas of a patient's dentition, so that the patient's bite is not affected when in use during treatment. On the other hand, the areas of embrasure or lateral surface are, ideally, relatively thicker to provide sufficient strength to push the tooth or teeth into their designated location to correct malocclusions. Often, these regions of embrasure are stretched thinner during the formation process for the oral appliance. In the formation of the oral appliance, the system described here can determine the areas of the oral appliance that affect the patient's bite and can configure the appliance to be thinner in particular areas or can even remove some material from the appliance entirely to form a hole.
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95/111 [00272] Reticular free-form structures that fit at least part of the surface, for example, external contour, of a part of the body, can be used to form the oral appliance. Specifically, the described embodiments may use reticular free-form structures for the formation or manufacture of appliances that are designed for placement or positioning on external surfaces of a patient's dentition to correct one or more malocclusions. The free-form structure is at least partially manufactured by additive manufacturing techniques and uses a basic structure comprised of a reticular structure. The reticular structure can guarantee and / or contribute to a free-form structure having a defined stiffness and the reticular structure can also guarantee ideal coverage over the dentition by a coating material that can be provided on the reticular structure. The reticular structure is at least partially covered, impregnated, and / or surrounded by the coating material. In addition, the achievements of the reticular structure can contribute to the transparency of the structure.
[00273] The term free-form reticular structure, as used herein, refers to a structure having an irregular or asymmetrical shape or contour, more particularly, adjusting at least part of the contour of one or more parts of the body. Thus, in particular embodiments, the freeform structure can be a freeform surface. A free-form surface refers to a (essentially) two-dimensional shape contained in a three-dimensional geometric space. In fact, as detailed here, this surface can be considered as essentially two-dimensional in that it has limited thickness, but can, to some degree, have varying thickness. Thus, it comprises an adjusted reticular structure
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96/111 rigidly to imitate a particular shape that forms a three-dimensional structure.
[00274] Typically, the free-form structure or surface is characterized by an absence of corresponding radial dimensions, different from regular surfaces, such as flat, cylindrical and conical surfaces. Freeform surfaces are known to the person skilled in the art and widely used in engineering design disciplines. Typically, non-uniform rational B-spline mathematics (NURBS) is used to describe surface shapes; however, there are other methods, such as Gorden surfaces or Coons surfaces. The shape of the freeform surfaces is characterized and defined not in terms of polynomial equations, but their poles, degree and number of fragments (segments with cooled curves). Freeform surfaces can also be defined as triangulated surfaces, where triangles are used to approximate 3D surfaces. Triangulated surfaces are used in Standard Triangulation Language (STL) files that are known to a technician in the subject of CAD design. Free-form structures adjust the surface of a part of the body, as a result of the presence of a basic rigid structure itself, which provides structures with their free-form characteristics.
[00275] The term rigid, when referring to the reticular structure and / or free-form structures comprising it here refers to a structure that presents a limited degree of flexibility, more particularly, the rigidity ensures that the structure forms and retains a shape predefined in a three-dimensional space before, during and after use and that this general shape is mechanically and / or physically resistant to the pressure applied to it. In particular designs, the structure is not foldable over
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97/111 itself, without substantially losing its mechanical integrity, manually or mechanically. Despite the general stiffness of the shape of the predicted structures, the specific stiffness of the structures can be determined by the structure and / or material of the reticular structure. In fact, it is predicted that reticular structures and / or free-form structures, while maintaining their general shape in a three-dimensional space, may have some (local) flexibility for manipulation. As will be detailed here, (local) variations can be followed by the nature of the lattice pattern, the thickness of the lattice structure and the nature of the material. In addition, as will be detailed below, when the freeform structures provided herein comprise separate parts (for example, non-continuous reticular structures) that are interconnected (for example, by hinges or areas of cladding material), the stiffness of the form may be limited to each of the areas comprising a reticular structure.
[00276] Descriptions of dental appliance manufacturing processes can be found in additional details in North American Provisional Order 62 / 238,514, filed on October 7, 2015, which is hereby incorporated by reference in its entirety and for any purpose.
[00277] In generally speaking, the manufacturing includes projection in a device used on the teeth a be covered by an free form structure, manufacturing
of the mold, and provision of (one or more) reticular structures therein and provision of the coating material in the mold, so as to form the structure freely. Free-form structures are patient-specific, that is, they are made to fit specifically in the anatomy or dentition of a particular patient, for example, animal or human. In the manufacture of the oral appliance, the 3D representation of
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98/111 surfaces, for example, external contours, of a patient's dentition to correct one or more malocclusions can be captured by a 3D scanner, for example, a hand held laser scanner, and the collected data can then be used to build a digital, three-dimensional model of the individual's body part. Alternatively, patient-specific images can be provided by a technician or health care provider when scanning the individual or part of it. These images can then be used as or converted to a three-dimensional representation of the individual, or part of him. Additional steps in which the scanned image is manipulated and, for example, cleaned, can be envisaged.
[00278] In the manufacture of oral or dental appliances that are used to treat malocclusions in a patient's dentition, the oral appliance can be initially formed, for example, by thermal formation or three-dimensional (3D) printing techniques. Once formed, the mouthpiece may need additional processing to finish the excess material to ensure a good fit on the patient. However, finishing this excess is typically a time-consuming process, which requires a separate step after the apparatus is formed.
[00279] In one embodiment, the formation and cutting of the mouthpiece can be carried out in an automatic process and with a single machine. In general, a patient's scanned dentition can be used to create one or more dentition molds in which each subsequent mold is configured to subsequently follow a corrective path for one or more teeth to correct malocclusions in the dentition. Each of the one or more molds can be used as a mold for thermal formation or 3D printing of a corresponding mouthpiece on the molds. The appliances
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Resulting 99/111 mouthpieces can be used in sequence to move the dentition to correct malocclusions.
[00280] Figure 23 presents an exemplary process for using computerized or numerical computer control (CNC) for the manufacture of oral appliances. Typical CNC systems and end-to-end component design is highly automatic using computer aided design (CAD) and computer aided manufacturing (CAM) dental software. The process begins by loading the digital models of the lower and upper 710 arches of the individual's dentition into a computer system having a processor. This may involve capturing the 3D representation of the surfaces, for example, external contours, of a patient's dentition to correct one or more malocclusions. For this purpose, the individual can be scanned using a 3D scanner, for example, a handheld laser scanner, and the collected data can then be used to build a digital, three-dimensional model of the individual's body part. Alternatively, patient-specific images can be taken by a technician or healthcare provider when scanning the individual or part of the individual. These images can then be used or converted into a three-dimensional representation of the individual, or part of it.
[00281] With the digital model of the individual's dentition loaded into the computer system, the process then calculates a cutting loop path based on rule 712 in the digital model to determine a path along which the CNC machine can proceed to finish the mold by which the mouthpiece is manufactured. Once the cutting loop path has been determined, the process can then reduce the complexity of the model by applying an overlay wall 714 (as described in more detail below) that digitally extends the loop path
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100/111 cut to the bottom of the mold model (for example, away from the part of the appliance that contacts the teeth and towards the part of the appliance that extends towards the gums). The overlapping wall works by defining a region of the mouthpiece that can be ignored, since that part must be removed or finished.
[00282] The digital model can then be rotated around its center in relation to a reference plane, in order to calculate an angle of inclination of the cutting blade and height of the blade 716 (in relation to the reference plane) that can be applied during the actual finishing procedure. With this information, the code to be sent to the CNC machine can be generated based on the stage configuration to be used 718. A physical mold base to be used in the processing procedure can be finished and one or more aspects of anchoring can be incorporated in the mold base to fix and retain the guide, which can be used to fix the mouthpiece 720 to the mold base. The complete digital model can then be exported, as, for example, in an acceptable model on a 3D printer 722, to print the mouthpiece or mold by which the mouthpiece can be formed.
[00283] Figures 24 and 25 show side views of part of a digital model of a patient's dentition showing a 730 tooth and 732 gums, as an example. In calculating a cutting loop path based on rule 712, as shown in Figure 23 above, a scanned image of a patient's dentition can be processed to identify areas of interface between teeth and gums 732. One or more markers 734 .736 can be placed digitally on the model in these interface regions, so that markers 734, 736 are opposite each other in the model. A 742 boundary or finish line can
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101/111 will then be defined to extend between markers 734, 736, so that the finish line 742 follows the edge between the teeth and gums. With the finishing line 742 identified in the model, a series of descending lines 738, 740 that are parallel to each other and spaced, for example, evenly, in relation to each other, can be formed to start from the finishing line 742 and extend away from the finishing line 742 and away from the dentition in a straight path. This base region 744 formed by the descending lines 738, 740 below the finishing line 742, that is, distant or opposite to the dentition, can be identified and demarcated as a region to be removed from the mold.
[00284] To ensure that the height of the mold, including the base region 744 does not excessively stretch the material that forms the mouthpiece, the system can be used to determine the lowest point (in relation to the finishing line 742 and appliance 730 ) to finish the entire mold just above that lowest point identified. In one embodiment, finishing may be carried out with a predetermined margin, for example, 2 mm, above the lowest point identified. The base region wall can also be tapered slightly based on the height of the base region wall, so that the width of the base region 744 tapers from a larger width adjacent to the finish line 742 down to a relatively wide smallest distant from the finishing line 742. The resulting mold formed from the dentition (or corrected dentition) is shown in the side view of Figure 25 where the base region 744 has a minimum height of the predetermined margin, for example, 2 mm.
[00285] Once the mold has been formed with the base region 744, the mold can be further processed. A bottom view of a mold formed 750 is
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102/111 shown in Figure 26 with slots 752, 754 formed on a surface 756 of the mold 750 where tools or anchors can be inserted to hold the mold 750 in place during additional processing procedures. Figure 27, for example, shows a side view of the manufactured mold 750, fixed along its interface surface 756 and anchored by slots 752, 754 to a surface 762 of a platform 760. Figure 28 shows a configuration in which the platform 760 that holds the physical mold 750 for pressure formation of the buccal aligner can be positioned from bottom to top, that is, so that the mold 750 is kept in an inverted position, as shown. Platform 760 can be fixed or held at a stage 768 that can be activated to move platform 760 and mold 750 in a vertical direction 764 (up / down) or linearly 766 within a plane defined by stage 768 and platform 760, as shown in Figure 28, to facilitate cutting or finishing processes for mold 750. Stage 768 can also be activated to rotate 770 to platform 760 and mold 750 within the plane defined by stage 768, so that stage 768 rotates over a axis that can be aligned to be co-linear to a central axis 772 of the mold 750, as shown in Figure 29.
[00286] Another configuration can position stage 768 in relation to a blade that can be moved and / or rotated in relation to mold 750 and stage 768. The system can calculate each of the parameters of movement stage and, while mold 750 is rotationally moved, the blade can be used to cut or finish the mold 750 as needed. This may involve rotating the model 750 over its center and calculating the blade tilt angle and blade height 716, as described above.
[00287] Yet, another configuration may involve the
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103/111 movement of stage 768 and mold 750 in relation to a fixed blade, so that the mold 750 is rotated, tilted and / or translated by stage 768, while the blade position remains unchanged. The system then adjusts different tools to finish the mold 750 on the pre-designated cutting path. In this or any other variation, the blade can include a mechanical blade or a laser cutting tool and software can be used to calculate the laser focus to more easily move the source back and force or attenuate its energy to focus and cut the 750 mold at designated locations.
[00288] In an implementation for processing the mold, Figure 30 shows a top view of a mold 750 positioned in a stage and rotated in relation to a fixed cutting blade 780. The mold 750 can be fixed to the base and stage platform and rotated within the plane of the platform in the direction 770 about its central axis 772 which can coincide with the axis of rotation defined by the stage. The cutting blade 780 having a cutting edge 782 can be positioned in relation to the mold at the predetermined height and angled with respect to the mold 750, as described herein, to finish the mold 750, as it rotates.
[00289] In this variation, instead of generating a complex 3D cutting curve, the system simply uses a 2D flat curve when optionally adjusting a watermark cutting plane. The advantage is that no numerical controller is needed to cut the molds. In contrast, mold 750 can simply be placed by hand and rotated (for example, manually or automatically), as shown, to push the 780 cutting blade forward or backward. The action may be similar to cutting a wooden board with a circular motion, rather than a straight or linear motion.
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104/111 [00290] Another advantage of this configuration is the ability to use a separate accessory that can be used to press the material that forms the mouthpiece after placing it on the mold, for example, when thermally forming the mouthpiece. The material from which the mouthpiece is thermally formed, if used for manufacturing, can be fixed directly, removing the need for yet another accessory in the mold itself. One implementation uses a two-dimensional (2D) laser cutting tool that can be used to cut along a flat curve formed by a horizontal silhouette line generated by a projection to the base surface.
[00291] Figure 31 shows a side view of an embodiment in which the mold 750 is positioned above a platform 760 with the plastic protection mold 792 after thermal formation on the mold 750. The whole of the mold 750, platform 760, and protective mold 792 rests on a flat bottom accessory base 790 having a fixture with one or more fixing plates 794, 796 on either side to secure mold 750 and protective mold 792. The accessory set can be used to fix the 792 protective mold for further processing as a finish. Once processing has been completed, the fixing plates 794, 796 can be released and the protective mold 792 and / or mold 750 can be removed from the accessory base 790.
[00292] In case the physical mold is processed by laser cutting, the steps presented in the flowchart of Figure 32 can be implemented in another realization. Initially, a digital model of the lower and upper arches can be loaded into the 800 system, as previously described. The system can then calculate a rule loop cutting path for the 2D cutting system
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105/111
802, as discussed above. The complexity of the model can be reduced by applying the cutting loop overlay wall 804, as discussed above. The process finishes the base of the mold above a watermark 806 which can be printed on the mold to demarcate a boundary. For laser cutters, the system can generate a 2D laser cutting path using 808 vertical designs and determine the shadow edge as the 810 cutting path. The system can then export the 3D printer model 812 for manufacturing. The process can be repeated for each subsequent mold used to manufacture one or more of the corresponding mouthpiece.
[00293] Regardless of how the mold is finished or how the mouthpiece is processed over the mold, separating and releasing the protection (aligner or mouthpiece) from the mold can, in general, be difficult due to the lack of any aspects for grab the mold. To address this, one or more holes or cavities 822 can be drilled or otherwise defined at various locations within the mold 820 and, optionally, at an angle 826 relative to a normal mold direction, as shown in the final view of the mold. Figure 33. The angle of the hole or cavity 822 allows the insertion of a tool 824 that can be positioned inside to provide a counter force to release and remove a mouthpiece 828 formed on the mold 820.
[00294] Another embodiment shown in the final view of Figure 34 that illustrates a final view of a mold 830 formed to have a hole or cavity 832 that extends through the bottom of the mold 830 and in the vicinity of the top of the mold, that is, where the model of a patient's dentition is located. A thin layer 834 of the mold can extend over orifice 832 to provide a surface on which
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106/111 the mouthpiece 828 can be manufactured as described herein. However, once the manufacture of the mouthpiece 828 has been completed and finished properly, the tip 838 of a properly sized tool 836 inserted into the opening 832 and pushed through the thin layer 834 of the mold 830 and in contact with an external surface of the mouthpiece, so that mouthpiece 828 can be stimulated to release from mold 830. Alternatively, tool 836 may comprise an air blower, so that tip 838 can be positioned inside opening 832 near the layer 834, as shown by the detail view D, in which a jet of air introduced through tip 838 can be broken through layer 834 and stimulate the mouthpiece 828 to release from the mold 830.
[00295] To ensure that the 830 mold retains its strength during the manufacture of the mold, mouthpiece, or release of the mouthpiece from the mold, the 830 mold can optionally be manufactured to include a beehive, mesh, or other porous aspect that outlines the mold surface 830. With the added structural strength provided by the hive or mesh, layer 834 can be broken or perforated and still allow air to pass through, but mold 830 can have the structural resilience to withstand the pressures generated by the protection formation on the surface of the 830 mold.
[00296] Figure 35 illustrates a flowchart for removing the mouthpiece manufactured on a mold, as described above. As previously described, the digital model of the lower and upper arches can be loaded into the 840 computer system. The system can then identify a suitable area along the 842 tool insertion model. This area can be located in a distant area of the teething model and so as not to interfere with the manufacture of the mouthpiece on the mold. The system can
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107/111 having the model finished by defining a hollow orifice of the 844 insert and to reinforce the hollow orifice, the system can then reshape the orifice area by forming the orifice region adjacent to which the dentition is modeled as a configuration of 846 mesh or beehive to provide resistance to the model, when manufactured, but which still allows air to pass through the openings defined by the mesh or beehive. The model can incorporate a receiving accessory to allow the insertion of tools and / or allows the fixation of the mold during removal of the mouthpiece from the 848 mold. Once the model has been completed, a model acceptable to the 3D printer can be exported 850 .
[00297] Figure 36 shows yet another exemplary embodiment to facilitate the removal of the manufactured oral appliance from the mold in the final view of the mold 860. The mold 860 can be formed to define an opening or channel 862 that extends through the mold 860 of a bottom (for example, opposite the part of the mold that replicates the dentition) towards a top (for example, part of the mold that replicates the dentition, such as occlusal surfaces). In this embodiment, a tapered structure 864 can be formed to be part of the mouthpiece 872 that is formed on the mold 860. The tapered structure 864 can remain attached to an internal surface of the mouthpiece while it is formed with a tapered surface 866 that changes from size to a larger diameter structure inside the opening or channel 862 away from the mouthpiece 872.
[00298] The tapered structure 864, once formed, can present a structure similar to cork that helps to affix the mouthpiece on the mold 860 during manufacture and processing. Once the 872 mouthpiece is completed and ready for release and removal of the 860 mold, a tool can be inserted into the opening or channel
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108/111
862, in the direction 870 as indicated, and used to carefully push in relation to the bottom surface of the tapered structure 864 to stimulate the release of the mouthpiece 872 from the mold 860 until the tapered structure 864 is removed entirely from the opening or channel 862, in the direction 868 , as indicated. Once the mouthpiece 872 has been removed entirely, the tapered structure 864 can be removed from the mouthpiece 872 as well.
[00299] Figure 37 illustrates a flow chart to remove the mouthpiece manufactured on a mold using the tapered structure 864, as described above. As previously described, the digital model of the lower and upper arches can be loaded into the 880 computer system. The system can then identify a suitable area along the model for inserting the 882 tool. This area can be located far from the dentition and so as not to interfere with the manufacture of the oral appliance on the mold. The system can finish the model by defining a hollow orifice of the insert 884 and to reinforce the hollow orifice, the system can then reshape the orifice area when forming or inserting the tapered structure 864 (for example, reverse cork-like structure ) 886. The model can incorporate a receiving accessory to allow the insertion of tools and / or allow the fixation of the mold during the removal 888 of the buccal appliance from the mold. Once the model has been completed, a model accepted by a 3D printer can be exported 890.
[00300] The system or method described here can be implemented in part or in whole by a computer system or machine having one or more processors that execute software programs with the methods, as described here. Software programs can be run on computer systems such as a server, domain server, Internet server, intranet server and others
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109/111 variations, such as secondary server, hosting server, distributed server, or other computer like that or networked hardware on a processor. The processor can be a part of a server, client, network infrastructure, mobile computing platform, fixed computing platform, or other computing platform. The processor can be any type of computing or processing device capable of executing program instructions, codes, binary instructions or the like that can directly or indirectly facilitate the execution of the program code or program instructions stored in itself. In addition, other devices necessary for the execution of methods as described in this application can be considered part of the infrastructure associated with the computer or server system.
[00301] The system or method described here can be implemented in part or as a whole by network infrastructures. The network infrastructure can include elements such as computing devices, servers, routers, hubs, firewalls, clients, wireless communication devices, personal computers, communication devices, routing devices, and other active and passive devices, modules or components , as known in the art. The computing device (s) or not associated with the network infrastructure may include, in addition to other components, a storage medium such as flash memory, temporary memory, stack, RAM, ROM or similar. The processes, methods, program codes and instructions described here and any part can be performed by one or more infrastructure elements of the network.
[00302] The elements described and depicted herein, including flowcharts, sequence diagrams, and others
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110/111 diagrams across all figures, imply logical limits between the elements. However, according to software or hardware engineering practices, the elements portrayed and their functions can be implemented on machines by means of computer-executable media having a processor capable of executing program instructions stored in them and all of these implementations can be within the scope of this document. Thus, although the previous drawings and descriptions establish functional aspects of the disclosed methods, no particular software provision to implement these functional aspects should be inferred from these descriptions, unless stated explicitly or otherwise clear from the context. Similarly, it will be realized that the various steps identified and described above can be varied and that the order of steps can be adapted to the particular applications of the techniques disclosed here. All such variations and modifications are intended to be within the scope of this document. As such, the portrayal or description of an order for several stages should not be understood as requiring a particular order of execution for those stages, unless necessary by a particular application, or stated explicitly or otherwise, of course. from the context.
[00303] Thus, in one aspect, each method described above and combinations of it can be performed in computer executable code that, when executed on one or more computing devices, performs its steps. In another aspect, the methods can be carried out in systems that carry out their steps, and can be distributed among devices in different ways, or all the functionality can be integrated with a standalone, dedicated device or other hardware. All of these permutations and combinations are
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111/111 intended to be within the scope of this disclosure.
[00304] The applications of the devices and methods discussed above are not limited to dental applications, but may include any number of additional treatment applications. In addition, these devices and methods can be applied to other treatment sites within the body. Modification of the sets and methods described above for carrying out the invention, combinations of different variations as practicable, and variations of aspects of the invention that are obvious to those skilled in the art are intended to be within the scope of the claims.

权利要求:
Claims (54)
[1]
1. METHOD FOR TREATING AN INDIVIDUAL, characterized by understanding:
reception of a scanned dental model of an individual's dentition;
determining a treatment plan having a plurality of additional movements to reposition one or more teeth of the individual's dentition; and fabricating one or more aligners that correlate to a first subset of the plurality of additional movements.
[2]
2. METHOD, according to claim 1, characterized by still comprising the reevaluation of the individual's dentition after a predetermined period of time to monitor the repositioning of one or more teeth.
[3]
METHOD, according to claim 2, characterized in that it also comprises the manufacture of one or more additional aligners that correlate to a second subset of the plurality of additional movements.
[4]
4. METHOD, according to claim 2, characterized by still comprising treatment of one or more teeth by a corrective measure without an aligner.
[5]
5. METHOD, according to claim 1, characterized by still comprising receipt of an entry from the individual regarding the treatment plan.
[6]
6. METHOD, according to claim 1, in which the reception of a scanned dental model is characterized by comprising the reception of a digital image of the individual's dentition.
[7]
7. METHOD according to claim 1, wherein
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2/10 the determination of a treatment plan is characterized by still understanding:
applying a mark to one or more teeth within the dental model;
simulation of a process of rolling spheres along an exterior of the one or more teeth and gums within the dental model;
determining a boundary between each of the one or more teeth and gums based on a path or trajectory of the rolling ball process;
assigning a rigid or soft region to each of the one or more teeth and gums within the dental model; and moving a position of one or more teeth within the dental model to correct malocclusions in the development of a treatment plan.
[8]
8. METHOD, according to claim 7, in which the application of a marking is characterized by comprising the reception of input from a user by a user interface in the application of the marking to one or more teeth within the dental model.
[9]
9. METHOD, according to claim 7, in which the simulation of a rolling ball process is characterized by understanding the detection of changes in a path of the rolling ball.
[10]
A method according to claim 7, wherein the determination of a limit is characterized by comprising the determination of a crown / gingival margin.
[11]
11. METHOD according to claim 7, in which the determination of a limit is characterized by comprising the
Petition 870190056980, dated 06/19/2019, p. 119/310
3/10 determining a boundary between adjacent teeth based on a projected trajectory of the scroll ball between the teeth.
[12]
12. METHOD according to claim 7, wherein the assignment of a hard or soft region is characterized by comprising assignment of rigid regions to one or more teeth and soft regions to the gums.
[13]
13. METHOD, according to claim 7, in which the movement of a position is characterized by understanding the application of a movement widget defined by the user to one or more teeth.
[14]
14. METHOD, according to claim 13, in which the movement widget is characterized by comprising widgets for medium / distal, lingual / facial or vertical operations.
[15]
15. METHOD according to claim 1, wherein the manufacture of one or more aligners is characterized by comprising 3D printing of the one or more aligners.
[16]
16. METHOD, according to claim 1, in which the determination of a treatment plan is characterized by still comprising:
determining a movement for a plurality of digital tooth models in the dental model to correct malocclusions by a tooth movement management module;
assigning a sphere of influence to each tooth model to establish a proximity distance between each tooth model by a collision management module;
monitoring a real state of each tooth of the
Petition 870190056980, dated 06/19/2019, p. 120/310
4/10 individual;
comparison of the actual state of each tooth in relation to an expected state of each tooth model using a tooth management module; and adjusting the movement of one or more teeth based on a comparison of the actual state and the expected state if a deviation is detected.
[17]
17. METHOD according to claim 16, wherein the determination of a movement is characterized by comprising the execution independently of a plane of movement of the tooth for each of the tooth models.
[18]
18. METHOD, according to claim 17, in which the execution in an independent manner is characterized by comprising simultaneous triggering of the beginning of the treatment plan by the multiple tooth models.
[19]
19. METHOD according to claim 16, in which the determination of a movement is characterized by comprising the assignment of one or more routes between an initial crossing point and a target crossing point.
[20]
20. METHOD, according to claim 19, wherein the comparison of the real state is characterized by comprising periodic comparison of the real state in relation to the expected state in each of the one or more paths.
[21]
21. METHOD according to claim 20, wherein the adjustment of the movement is characterized by comprising the assignment of a new crossing point to one or more of the tooth models if deviation is detected.
[22]
22. METHOD according to claim 16, wherein the adjustment of the movement is characterized by comprising the adjustment of a speed or course of movement of the one or more
Petition 870190056980, dated 06/19/2019, p. 121/310
5/10 teeth.
[23]
23. METHOD according to claim 16, wherein the adjustment of the movement is characterized by comprising adjustment based on interrelationships of skeletal and soft tissue.
[24]
24. METHOD, according to claim 16, wherein the allocation of a sphere of influence is characterized by comprising allocation of a space of 1 to 3 mm over each of the tooth models.
[25]
25. METHOD, according to claim 16, in which the allocation of a sphere of influence is characterized by still comprising monitoring by a collision between tooth models.
[26]
26. METHOD, according to claim 25, characterized by still comprising the communication of a collision alert to an adjacent tooth model, so that one or more of the tooth models changes its movement to avoid collision.
[27]
27. METHOD, according to claim 1, wherein the manufacture of one or more aligners is characterized by still comprising:
generating a free-form structure having a reticular structure that corresponds to at least part of a dentition surface, where the reticular structure defines a plurality of open spaces, so that the free-form structure is at least partially transparent; and fabricating the reticular structure by impregnating or covering a coating on or over the reticular structure so that the mouthpiece is formed.
[28]
28. METHOD, according to claim 27,
Petition 870190056980, dated 06/19/2019, p. 122/310
6/10 characterized by still comprising the generation of one or more additional freeform structures and the manufacture of one or more additional freeform structures to form one or more additional mouthpieces, each of which one or more additional mouthpieces are configured to correct malocclusions within the dentition.
[29]
29. METHOD according to claim 27, in which the generation of a free-form structure is characterized by still comprising the determination of a force necessary to move a tooth and modification of a thickness of the free-form structure in the vicinity of the tooth .
[30]
30. METHOD according to claim 29, wherein determining a force is characterized by comprising performing a simulation to confirm a stress point for the freeform structure in the vicinity of the tooth.
[31]
31. METHOD, according to claim 27, in which the generation of a free-form structure is characterized by comprising, having the reticular structure, definition of a plurality of open spaces that are uniform with each other.
[32]
32. METHOD, according to claim 27, in which the generation of a free-form structure is characterized by comprising, having the reticular structure, definition of a plurality of open spaces that vary in relation to each other.
[33]
33. The method of claim 27, wherein generating a free-form structure is characterized by comprising varying the thickness of the reticular structure.
Petition 870190056980, dated 06/19/2019, p. 123/310
7/10
[34]
34. The method of claim 27, wherein the fabrication of the reticular structure is characterized by comprising varying the thickness of the coating.
[35]
35. METHOD, according to claim 27, wherein the fabrication of the reticular structure is characterized by still comprising the definition of one or more characteristics on the oral apparatus.
[36]
36. METHOD according to claim 1, in which the manufacture of one or more aligners is characterized by still comprising:
manufacture of a support structure that corresponds to an external dentition surface;
forming one or more mouthpieces on an outer surface of the support structure so that an interior of the one or more mouthpieces conforms to the dentition; and removing the support structure from the interior of the one or more oral appliances.
[37]
37. METHOD according to claim 36, wherein the formation of one or more oral appliances is characterized by comprising the formation of one or more oral appliances in a sequence configured to move one or more teeth of the individual to correct malocclusions.
[38]
38. METHOD according to claim 36, wherein the manufacture of a support structure is characterized by comprising the manufacture of the support structure of a first material and formation of one or more oral appliances of a second material different from the first material .
[39]
39. METHOD, according to claim 38, characterized by the first material facilitating the separation of the
Petition 870190056980, dated 06/19/2019, p. 124/310
8/10 second material, so that the one or more oral appliances are removable from the support structure.
[40]
40. METHOD according to claim 36, wherein the formation of one or more oral appliances is characterized by comprising the formation of one or more dental displays on the oral appliances.
[41]
41. The method of claim 36, wherein the formation of one or more oral appliances is characterized by increasing the thickness of one or more parts of the oral appliances to reinforce one or more parts.
[42]
42. The method of claim 36, wherein the formation of one or more oral appliances is characterized by comprising the formation of a relatively thin layer over a region of the oral appliance configured to contact an area of the occlusal dentition.
[43]
43. METHOD according to claim 36, wherein the formation of one or more buccal appliances is characterized by comprising the formation of a relatively thicker layer in an area of embrasure or lateral surface of the buccal apparatus to provide pushing force one or more teeth at a predetermined location.
[44]
44. METHOD according to claim 36, wherein the formation of one or more oral appliances is characterized by comprising the impression of one or more oral appliances having varying thicknesses.
[45]
45. METHOD according to claim 36, wherein the formation of one or more oral appliances is characterized by comprising impregnating or covering at least part of the oral appliance with a transparent polymer.
Petition 870190056980, dated 06/19/2019, p. 125/310
9/10
[46]
46. METHOD according to claim 1, wherein the manufacture of one or more aligners is characterized by still comprising:
calculation of a cutting loop path based on the model rule to determine a path for finishing a mold that replicates the patient's dentition;
application of a cutting loop overlay wall on the model to reduce model complexity;
determining a position of a cutting instrument in relation to the mold for finishing the mold;
generation of a computer numerical control code based on the overlapping wall and position of the cutting instrument; and mold manufacturing based on computer generated numerical control code.
[47]
47. METHOD according to claim 46, wherein the calculation of a rule-based cutting loop path is characterized by comprising the identification of a first location and a second location opposite the first location opposite the first location in the model in corresponding interface regions and extending a finishing line between the first location and the second location.
[48]
48. METHOD, according to claim 47, wherein the application of an overlapping wall is characterized by comprising the identification of the finishing line and replacing a volume below the finishing line with a base region.
[49]
49. METHOD according to claim 46, wherein the application of an overlapping wall is characterized
Petition 870190056980, dated 06/19/2019, p. 126/310
10/10 for understanding limitation of a height of the overlapping wall to avoid stretching of a mouthpiece formed on the mold.
[50]
50. METHOD according to claim 46, wherein the manufacture of the mold is characterized by comprising fixing the mold to a platform.
[51]
51. METHOD, according to claim 50, characterized in that it also comprises fixing the mold and platform on one or more stages.
[52]
52. METHOD, according to claim 51, characterized in that it also comprises the rotation of the mold in relation to the cutting instrument.
[53]
53. METHOD, according to claim 51, characterized in that it also comprises the rotation of the cutting instrument in relation to the mold.
[54]
54. METHOD, according to claim 46, wherein the mold manufacture is characterized by further comprising placing an opening or hole in a mold base to receive a tool to facilitate the removal of a mouthpiece from the mold.

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同族专利:

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公开号 | 公开日

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JP2020503919A|2020-02-06|

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法律状态:
2021-04-20| B06W| Patent application suspended after preliminary examination (for patents with searches from other patent authorities) chapter 6.23 patent gazette]|

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2021-10-13| B350| Update of information on the portal [chapter 15.35 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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US15/386,280|US10548690B2|2015-10-07|2016-12-21|Orthodontic planning systems|

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PCT/US2017/057375|WO2018118200A1|2016-12-21|2017-10-19|Orthodontic planning systems|

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