System for producing a dental implant and method

• US 20050142517A1
• Filed: 10/28/2004
• Published: 06/30/2005
• Est. Priority Date: 12/30/2003
• Status: Abandoned Application

• Current Assignee: D4D Technologies L P (D4D Technologies)
• Original Assignee: D4D Technologies L P (D4D Technologies)
• Inventors: Quadling, Henley S., Quadling, Mark S., Frysh, Howard
• Application Number:
  US10/975,515
• Publication Number:
  US 20050142517A1
• Time in Patent Office: Days
• US Class Current: 433/173
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 5/77 Methods or devices for making crowns
• CPC Class Codes: A61C 9/0053 Optical means or methods, e.g. scanning the teeth by a laser or light beam

Abstract

A system and method for producing a dental fixture are provided. A laser digitizer imaging system creates a visual three-dimensional image of a dental item such as a tooth or a dental impression. The three-dimensional image may be displayed and the size and shape of the image may be selectively modified by the user of the system. Digital data associated with the three-dimensional image of the dental item is sent to an implant production device. A dental implant is produced in response to receipt of the data associated with the three-dimensional image such that the implant is insertable into a socket of the jawbone from where a tooth was extracted.

Claims

1. A method of producing a dental fixture, comprising:

creating a three-dimensional image of at least a portion of a dental item;

sending data associated with the three-dimensional image to an implant production device; and

producing a dental implant in response to receipt of the data associated with the three-dimensional image.

2. The method of claim 1 wherein the dental item comprises at least one of:

a) a tooth and b) a dental impression.

3. The method of claim 2 further comprising imaging the dental item after it is removed from a mouth.

4. The method of claim 2 further comprising imaging the dental item with an intra-oral laser digitizer imaging system before it is removed from a mouth.

5. The method of claim 2 wherein the dental item is a tooth and further comprising forming the dental implant to mimic a shape of at least a portion of a root of the tooth.

6. The method of claim 2 further comprising milling a solid piece of material at the implant production device to form the dental implant based on the data received from an imaging system.

7. The method of claim 6 further comprising inserting, into the implant production device, a blank of the solid piece of material that has a shape that is similar to a shape of the dental implant to be produced.

8. The method of claim 6 wherein the solid piece of material is comprised of titanium blank and the implant production device is a milling machine.

9. The method of claim 8 further comprising utilizing tools that are manipulated on an x-axis carriage to mill the titanium blank.

10. The method of claim 9 further comprising holding a first and a second tool in a first and a second spindle coupled to the x-axis carriage, and advancing the first and second spindles such that the first and second tools contact the titanium blank.

11. The method of claim 10 further comprising positioning the titanium blank using a y-axis carriage and a z-axis carriage.

12. The method of claim 6 further comprising adjusting data associated with a size of the three-dimensional image to produce the dental implant with a size that is different than the portion of the dental item being imaged.

13. The method of claim 12 further comprising enlarging a thickness of a portion of the implant relative to a corresponding portion of the dental item being imaged.

14. The method of claim 12 further comprising modifying data associated with a root portion of the image of the dental item such that a corresponding root portion of the dental implant is omitted by the implant production device.

15. The method of claim 12 further comprising selectively modifying data associated with a surface of the three-dimensional image of the portion of the dental item, and producing the dental implant to have a surface associated with the modified surface of the imaged portion of the dental item.

16. The method of claim 12 further comprising displaying the three-dimensional image of the dental item.

17. The method of claim 6 wherein the dental item is a tooth and further comprising selectively modifying a shape of the three-dimensional image such that the produced dental implant is able to be seated into a fresh socket of a jawbone which previously held the tooth, to stabilize the implant in the jawbone and restrict growth of soft tissue into the socket.

18. The method of claim 17 further comprising modifying the shape of the three-dimensional image to create an abutment portion extending from a root portion of the three-dimensional image,

positioning the abutment portion of the three-dimensional image at an angle relative to the root portion of the three-dimensional image to mimic an angle between a root portion of the tooth and a non-root portion of the tooth.

19. The method of claim 6 further comprising forming the dental implant with a relatively wide portion proximate to an occlusal part of the implant.

20. The method of claim 6 further comprising modifying the data associated with the three-dimensional image to design an abutment portion of the three-dimensional image of the dental item, and

producing, at the implant production device, an abutment portion as part of the dental implant such that the abutment portion of the dental implant is positioned at an occlusal part of the dental implant.

21. The method of claim 20 wherein the abutment portion of the dental implant corresponds to the design for the abutment portion of the three-dimensional image in accordance with the modified data.

22. The method of claim 20 further comprising placing a prosthesis over at least a portion of the abutment portion of the dental implant.

23. The method of claim 6 further comprising forming an abutment as part of the dental implant.

24. The method of claim 23 further comprising imaging a crown portion of a tooth,

sending information associated with the imaged crown portion of the tooth to the implant production device, and

producing a dental crown prosthesis at the implant production device in response to receipt of the information associated with the crown portion of the tooth.

25. The method of claim 6 further comprising scanning a multi-axis collimated beam of light in a predetermined pattern, where the pattern includes a plurality of substantially parallel curves,

focusing the scanned collimated beam of light on the dental item,

capturing an image of the formed collimated beam of light on the dental item during an exposure period, and

determining a map of a surface of at least a portion of the dental item based on the captured image.

26. The method of claim 25 further comprising placing the dental item in an object positioning device configured to position the dental item within a field of projection for a scanner.

27. The method of claim 6 further comprising utilizing optical coherence tomography to image a root portion of the dental item.

28. The method of claim 2 wherein the dental item is a dental impression and further comprising inserting impression material into a socket of a mouth of a patient to form the dental impression,

imaging at least a portion of the dental impression, and

preparing the dental implant at an implant production device in response to imaging at least a portion of the dental impression.

29. The method of claim 28 further comprising extracting a tooth from the mouth of the patient,

performing dental procedures to the socket from where the tooth was extracted to create a prepared site, and

inserting the impression material into the prepared site.

30. A dental implant production system, comprising:

an imaging system that creates a three-dimensional image of at least a portion of a dental item; and

an implant productional device coupled to the imaging system which receives data associated with the three-dimensional image of the dental item, the implant production device produces a dental implant in response to receipt of the data associated with the three-dimensional image.

44. The system of claim 30 wherein the dental item comprises a tooth and further comprising a user interface coupled with the imaging system, the imaging system, in response to user input at the user interface, selectively adjusts data associated with the shape of the three-dimensional image such that the dental implant produced at the implant production device is able to be seated into a fresh socket of a jawbone which previously held the tooth.

45. The system of claim 44 wherein the imaging system, in response to user input at the user interface, is capable of selectively adjusting the shape of the three-dimensional image such that the implant production device forms the dental implant with a relatively wide portion proximate a top end of the implant.

46. The system of claim 44 wherein the implant production device is capable of producing the dental implant with a facility to screw an abutment into the dental implant.

47. The system of claim 30 wherein the imaging system is a laser digitizer imaging system which comprises a light source having collimating optics configured to generate a collimated beam of light,

a scanner optically coupled to the light source and configured to scan the collimated beam along at least two axes towards the tooth to be imaged,

an image capture instrument having an optical axis at an angle θ

with respect to the scanner and configured to detect a reflection of the scanned beam from the object and to generate data representative of a surface of the tooth based on the reflected beam, and

a processor coupled to the scanner and the image capture system configured to generate the three-dimensional image of the dental item based on the data.

48. The system digitizer of claim 47 further comprising a flat-field scan lens having an optical axis and configured to focus the scanned beam of light to a point on the dental item to be imaged.

49. The system of claim 48 where the image capture instrument comprises:

an image sensor configured to detect a triangulation image of the dental item, the triangulation image based on a plurality of curves generated by scanning the beam of light on the dental item during an exposure period, and

a telecentric lens configured to focus the plurality of curves on the image sensor.

50. The system of claim 49 further comprising an object positioning system configured to position the dental item within a field of projection of the scanner.

51. The system of claim 50 where the object positioning system is configured to move the dental item to various positions and angles with respect to a field of view of the image sensor instrument and the scanner.

52. The system of claim 51 where the processor is programmed to merge multiple images of the dental item to create a three-dimensional map of the dental item.

53. The system of claim 48 where the scanner further comprises a programmable position controller configured to control the scan of the collimated laser beam to a programmed scan sequence.

31. The system of 30 wherein the dental item comprises at least one of:

a) a tooth and b) a dental impression.

32. The system of claim 31 wherein the dental item is a tooth and the implant production device forms the dental implant to mimic a shape of at least a portion of a root of the tooth.

33. The system of claim 32 wherein the imaging system includes a scanner which optically scans the root of the tooth.

34. The system of claim 32 wherein the imaging system is an intra-oral laser digitizer imaging system that images a root portion of the tooth before it is removed from a mouth.

35. The system of claim 34 in which the intra-oral laser digitizer imaging system utilizes optical coherence tomography to image the root portion of the tooth.

36. The system of claim 31 wherein the implant production device is a milling machine which is programmable to mill a solid piece of material to form the dental implant based on the data received from the imaging system.

37. The system of claim 36 wherein the solid piece of material comprises a titanium blank.

38. The system of claim 37 wherein the titanium blank has a shape that is similar to a shape of the dental implant to be produced.

39. The system of claim 37 in which the milling machine further comprises an x-axis carriage having a first spindle and a second spindle that are axially aligned, a y-axis carriage that adjusts the position of the titanium blank, and a z-axis carriage.

40. The system of claim 39 further comprising a first tool and a second tool held at the first spindle and second spindle respectively for milling the titanium blank.

41. The system of claim 31 further comprising a user interface coupled with the imaging system which allows for selective adjustment of a size of the three-dimensional image such that the implant production device can produce a dental implant having a size that is different than the portion of the dental item being imaged.

42. The system of claim 41 further comprising a display device coupled with the imaging system that displays the three-dimensional image of the dental item.

43. The system of claim 42 wherein the imaging system modifies data associated with a surface of the three-dimensional image in response to user input at the user interface, and wherein the implant production device responsively produces the dental implant having a surface associated with the data for the modified surface of the imaged portion of the dental item.