Mass production of shells and models for dental restorations produced by solid free-form fabrication methods

• US 20020064745A1
• Filed: 09/05/2001
• Published: 05/30/2002
• Est. Priority Date: 07/10/1998
• Status: Active Grant

• Current Assignee: Pentron Clinical Technologies, LLC (Danaher Corporation)
• Original Assignee: Jeneric/Pentron Incorporated (Danaher Corporation)
• Inventors: Panzera, Carlino, Schulman, Martin L.
• Granted Patent: US 6,821,462 B2
• Time in Patent Office: Days
• US Class Current: 433/2
• CPC Class Codes: A61C 13/0003 Making bridge-work, inlays, implants or the like
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61K 6/17 Particle size
• CPC Class Codes: A61K 6/802 comprising ceramics
• CPC Class Codes: A61K 6/818 comprising zirconium oxide
• CPC Class Codes: A61K 6/82 comprising hafnium oxide
• CPC Class Codes: A61K 6/827 Leucite
• CPC Class Codes: A61K 6/838 Phosphorus compounds, e.g. apatite
• CPC Class Codes: A61K 6/84 comprising metals or alloys
• CPC Class Codes: A61K 6/849 comprising inorganic cements
• CPC Class Codes: A61K 6/884 comprising natural or synthetic resins
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell used in the manufacture of a dental restoration. Three-dimensional printing comprises ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously. While the layers become hardened or at least partially hardened as each of the layers is laid down, once the desired final shaped configuration is achieved and the layering process is complete, in some applications it may be desirable that the form and its contents be heated, cooled or cured at a suitably selected temperature to further promote the integrity of solid free-form structures.

Claims

1. A process for manufacturing a shell used in the manufacture of a dental restoration comprising:

(a) using digitized data to provide a shape for the shell;

(b) depositing a layer of a polymeric material; and

(c) repeating step (b) a number of times to produce a number of layers of the polymeric material which are bonded to one another to form the a shape of the shell based on the digitized data.

2. The process of claim 1 wherein the polymeric material comprises a thermoplastic material.

3. The process of claim 1 wherein the polymeric material comprises wax, plastic, rubber, composite material or mixture thereof.

4. The process of claim 3 wherein the wax material comprises a wax having a modulus of elasticity below about 10 GPa.

5. The process of claim 1 further comprising (d) applying a bonding material onto the polymeric layer.

6. The process of claim 1 wherein the polymeric layer is hardened before the deposition of another layer.

7. The process of claim 1 wherein the polymeric layer is deposited in a dry state.

8. The process of claim 1 wherein the polymeric layer material is deposited in a wet state.

9. The process of claim 1 wherein the digitized data comprises a selected pattern.

10. The process of claim 9 wherein the selected pattern is based on a computer assisted design.

11. A shell used for the manufacture of a dental restoration formed by the method of claim 1.

14. The process of claim 13 wherein the model material comprises gypsum or epoxy material.

15. A dental restoration formed by the process of claim 12.

17. The process of claim 16 wherein the coping is in the shape of denture teeth, a bridge, crown, space maintainers, tooth replacement appliance, orthodontic retainer, denture, post, jacket, inlay, onlay, facing, veneer, facet, implant, abutment, splint, partial crown, cylinder, pin, or connector.

19. The process of claim 18 wherein the powder material comprises a polymeric material.

20. The process of claim 19 wherein the polymeric material comprises a thermoplastic material.

21. The process of claim 19 wherein the polymeric material comprises wax, plastic, rubber, composite material or mixture thereof.

22. A shell used in the manufacture of a dental restoration manufactured by the process of claim 18.

24. The process of claim 23 wherein the mixture is dispensed in the form of a bead.

25. The process of claim 24 wherein the bead comprises a slurry or a liquidfied filament.

26. The process of claim 25 wherein the slurry comprises a wax, plaster, plastic, rubber, or composite material or mixture thereof.

27. The process of claim 25 wherein the liquified filament comprises wax, plaster, plastic, rubber, or composite material or mixture thereof.

28. A shell used in the manufacture of a dental restoration manufactured by the process of claim 23.

30. The process of claim 29 wherein the polymeric material comprises a wax, plaster, plastic, rubber, or composite material or mixture thereof.

31. A shell used in the manufacture of a dental restoration manufactured by the process of claim 29.

12. A process for manufacturing a dental restoration comprising:

manufacturing a shell by rapid prototyping;

filling the shell with refractory material to form a model;

removing the model from the shell; and

applying ceramic, metal or composite material on the model to form a dental restoration.

13. A process for manufacturing a dental restoration comprising:

manufacturing a shell by rapid prototyping;

filling the shell with dental model material to form a master model;

removing the master model from the shell;

duplicating the master model to form a working model; and

applying ceramic, metal or composite material on the working model to form a dental restoration.

16. A process for manufacturing a dental restoration comprising:

manufacturing a shell by rapid prototyping, wherein the shell is a replica of a coping;

covering the shell with refractory material;

burning out the shell to provide a space in the refractory material;

filling the space with ceramic, metal or composite material to form the dental restoration.

18. A process for manufacturing a shell used in the manufacture of a dental restoration comprising:

(a) using digitized data to provide a shape for the shell;

(b) depositing a preselected quantity of powder material;

(c) spreading the powder material in a layer of preselected thickness over a predetermined region;

(d) applying a binder material to selected regions of the powder material to cause the powder material to become bonded at the selected regions; and

(e) repeating steps (b), (c) and (d) a number of times to produce a number of successive layers whereby the successive layers become bonded to one another at the selected regions to form the shell based on the digitized data.

23. A process for producing a shell used in the manufacture of a dental restoration comprising:

(a) using digitized data to provide a shape for the shell;

(b) providing a mixture of powder material dispersed in a binder; and

(c) dispensing the mixture from a dispensing apparatus onto a platform based on the digitized data to build a three dimensional shell.

29. A process for forming a shell used in the manufacture of a dental restoration comprising:

(a) using digitized data to provide a shape for the shell;

(b) supplying polymeric material to a dispensing apparatus; and

(c) dispensing the polymeric material from a dispensing apparatus onto a platform to build a three dimensional shell based on the digitized data.

32. A process for manufacturing a model used in the manufacture of a dental restoration comprising:

(a) depositing a layer of a investment material;

(b) repeating step (a) a number of times to produce a number of layers of the investment material which are bonded to one another to form a shape of the model; and

(c) curing the shaped material to form the model.

33. The process of claim 32 wherein the investment material comprises gypsum.

34. The process of claim 32 wherein the investment material comprises a refractory material and a binder.

35. The process of claim 34 wherein the refractory material comprises quartz, cristobalite, silica, leucite, zirconia, hafnia, zircon, alumina, magnesia, zircon, aluminosilicate, cordierite, mica, silicon nitride, silicon carbide, silica-alumina-nitrides, mullite, garnet, or mixtures thereof.

36. The process of claim 34 wherein the binder comprises an inorganic material, an organic material, or mixtures thereof.

37. The process of claim 36 wherein the organic material comprises polyvinyl pyrrolidine, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyvinyl butryal and polystyrene, or mixtures thereof.

38. The process of claim 36 wherein the inorganic material comprises magnesium oxide, ammonium phosphate, colloidal silica, calcium sulfate, magnesium phosphate, alkaline silicates, silica hydrosol, colloidal clays, or mixtures thereof.

39. The process of claim 32 wherein the investment material layer is cured before the deposition of another layer.

40. The process of claim 32 wherein the investment material layer is deposited in a dry state.

41. The process of claim 32 wherein the investment material layer is deposited in a wet state.

42. The process of claim 32 wherein the investment material layer forms a selected pattern.

43. The process of claim 32 wherein the selected pattern is based on a computer assisted design.

44. A model used for the manufacture of a dental restoration formed by the method of claim 32.

46. The process of claim 45 wherein the powder material comprises an investment material.

47. The process of claim 46 wherein the investment material comprises a refractory material and a binder.

48. The process of claim 47 wherein the refractory material comprises quartz, cristobalite, silica, leucite, zirconia, hafnia, zircon, alumina, magnesia, zircon, aluminosilicate, cordierite, mica, silicon nitride, silicon carbide, silica-alumina-nitrides, mullite, garnet, or mixtures thereof.

49. The process of claim 47 wherein the binder comprises an inorganic material, an organic material, or mixtures thereof.

50. The process of claim 49 wherein the organic material comprises pyrrolidine, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyvinyl butryal and polystyrene, or mixtures thereof.

51. The process of claim 49 wherein the inorganic material comprises magnesium oxide, ammonium phosphate, colloidal silica, calcium sulfate, magnesium phosphate, alkaline silicates, silica hydrosol, colloidal clays, or mixtures thereof.

52. A model used in the manufacture of a dental restoration manufactured by the process of claim 45.

45. A process for manufacturing a model used in the manufacture of a dental restoration comprising:

(a) depositing a preselected quantity of powder material;

(b) spreading the powder material in a layer of preselected thickness over a predetermined region;

(c) applying a binder material to selected regions of the powder material to cause the powder material to become bonded at the selected regions; and

(d) repeating steps (a), (b) and (c) a number of times to produce a number of successive layers whereby the successive layers become bonded to one another at the selected regions.

53. A process for producing a model used in the manufacture of a dental restoration comprising:

providing a mixture of powder material dispersed in a binder;

dispensing the mixture from a dispensing apparatus onto a platform to build a three dimensional model.

54. The process of claim 53 wherein the mixture is dispensed in the form of a bead.

55. The process of claim 54 wherein the bead comprises a slurry or a liquiefied filament.

56. The process of claim 53 wherein the powder material comprises a refractory material.

57. The process of claim 56 wherein the refractory material comprises quartz, cristobalite, silica, leucite, zirconia, hafnia, zircon, alumina, magnesia, zircon, aluminosilicate, cordierite, mica, silicon nitride, silicon carbide, silica-alunina-nitrides, mullite, garnet, or mixtures thereof.

58. A model used in the manufacture of a dental restoration manufactured by the process of claim 53.

60. The process of claim 59 wherein the investment material comprises a refractory material and a binder.

61. The process of claim 60 wherein the refractory material comprises quartz, cristobalite, silica, leucite, zirconia, hafnia, zircon, alumina, magnesia, zircon, aluminosilicate, cordierite, mica, silicon nitride, silicon carbide, silica-alumina-nitrides, mullite, garnet, or mixtures thereof.

62. The process of claim 60 wherein the binder comprises an inorganic material, an organic material, or mixtures thereof.

63. The process of claim 62 wherein the organic material comprises pyrrolidine, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, polyvinyl butryal and polystyrene, or mixtures thereof.

64. The process of claim 62 wherein the inorganic material comprises magnesium oxide, ammonium phosphate, colloidal silica, calcium sulfate, magnesium phosphate, alkaline silicates, silica hydrosol, colloidal clays, or mixtures thereof.

65. A model used in the manufacture of a dental restoration manufactured by the process of claim 59.

59. A process for forming a model used in the manufacture of a dental restoration comprising:

supplying investment material to a dispensing apparatus; and

dispensing the investment material from a dispensing apparatus onto a platform to build a three dimensional model.

66. A process for manufacturing a dental restoration comprising:

manufacturing a model by rapid prototyping;

applying ceramic, metal or composite material on the model to form a dental restoration.

68. The process of claim 67 wherein the polymeric material comprises wax, plastic, rubber, composite material or mixture thereof.

69. The process of claim 68 wherein the wax material comprises a wax having a modulus of elasticity below about 10 GPa.

70. The process of claim 67 wherein the polymeric layer is cured before the deposition of another layer.

71. The process of claim 67 wherein the polymeric layers form a selected pattern.

72. The process of claim 67 wherein the selected pattern is based on a computer assisted design.

73. A model used in the manufacture of a dental restoration manufactured by the process of claim 67.

67. A process for manufacturing a model used in the manufacture of a dental restoration comprising:

(a) depositing a layer of a polymeric material; and

(b) repeating step (a) a number of times to produce a number of layers of the polymeric material which are bonded to one another to form a shape of the shell.

74. A process for manufacturing a dental restoration comprising:

manufacturing a master model by rapid prototyping;

wherein the master model is fabricated of a polymeric material;

duplicating the master model to provide a working model, wherein the working model is fabricated of an investment material;

applying ceramic, metal or composite material on the working model to form a dental restoration.

75. The process of claim 74 wherein the investment material comprises a refractory material.