Three-dimensional printing methods and materials for making dental products

• US 20090148813A1
• Filed: 08/29/2008
• Published: 06/11/2009
• Est. Priority Date: 08/31/2007
• Status: Abandoned Application

• Current Assignee: Andrew Lichkus, Benjamin J. Sun, Christopher R. Kennedy
• Original Assignee: Andrew Lichkus, Benjamin J. Sun, Christopher R. Kennedy
• Inventors: Kennedy, Christopher R., Sun, Benjamin J., Lichkus, Andrew
• Application Number:
  US12/231,079
• Publication Number:
  US 20090148813A1
• Time in Patent Office: Days
• US Class Current: 433/201.100
• CPC Class Codes: A61C 13/0001 In-situ dentures; Trial or temporary dentures
• CPC Class Codes: A61C 13/0019 using three dimensional printing
• CPC Class Codes: A61C 19/003 Apparatus for curing resins by radiation
• CPC Class Codes: A61K 6/887 Compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61K 6/891 Compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: A61K 6/893 Polyurethanes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C08L 33/04 Homopolymers or copolymers of esters C08L43/04 takes precedence
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence
• CPC Class Codes: C08L 75/16 having terminal carbon-to-carbon unsaturated bonds

Abstract

This invention relates to ink-jet printing systems for making dental products such as artificial teeth, dentures, splints, veneers, inlays, onlays, copings, frame patterns, crowns and bridges and the like. An ink-jet printer is used to discharge wax-like polymerizable material in a layer-by-layer manner to build-up the object. In other methods, a heated capillary or dropper can be used to apply the polymerizable material. The resulting three-dimensional object has good dimensional stability. Light irradiation can be used to cure and harden the material, thereby producing the final dental product.

Claims

1. A method for making a three-dimensional dental prosthesis containing multiple cross-sectional layers, comprising the steps of:

a. applying wax-like polymerizable material onto a support surface to form a multi-layered, uncured prosthesis, each layer of the prosthesis being formed by an ink-jet printer jetting the polymerizable material onto the support surface;

b. placing the prosthesis in the mouth of a patient and shaping the prosthesis over a targeted area by applying sufficient pressure;

c. removing the shaped prosthesis from the mouth;

d. irradiating the prosthesis with curing light so that the prosthesis fully cures and hardens.

2. The method of claim 1, wherein the polymerizable material comprises a polymerizable acrylic compound and polymerization initiation system capable of being activated by light.

3. The method of claim 2, wherein the polymerizable material comprises a mixture of polymerizable acrylic oligomers and monomers.

4. The method of claim 2, wherein the polymerizable material further comprises particulate filler.

5. The method of claim 4, wherein the particulate filler is selected from the group consisting of silica, alumina, silicon nitride, and glass compounds.

6. The method of claim 2, wherein the polymerization initiation system comprises a photoactive agent selected from the group consisting of camphorquinone;

2,4,6 trimethylbenzoyldiphenyl phosphine oxide; and

ethyl (4-N,N-dimethylamino) benzoate.

7. The method of claim 2, wherein the polymerizable material further comprises pigment.

8. The method of claim 7, wherein the pigment is selected from organic and inorganic pigments.

9. The method of claim 7, wherein the pigment is selected from the group consisting of black iron oxide 7053, yellow iron oxide 7055, titanium dioxide, cromophtal red-BRN 2-napthalenecarboxamide, N,N′

-(2-chloro-1,4-phenylene) bis{4-{(2,5-dichlorophenyl)azo}-3-hydroxy-}, ultramarine blue, brown iron oxide 420, and mixtures thereof.

10. The method of claim 1, wherein the prosthesis is irradiated with blue visible light having a wavelength in the range of about 400 to about 500 nm.

11. The method of claim 1, wherein the patient bites down prior to removing the uncured prosthesis from the mouth so that the fit of the prosthesis can be checked.

12. The method of claim 1, wherein a separating material is jetted from the ink-jet printer and deposited between the supporting material and wax-like polymerizable material.

13. A method for making a three-dimensional dental prosthesis containing multiple cross-sectional layers, comprising the steps of:

a. applying wax-like polymerizable material into a powder bed comprising particulate powder material to form a multi-layered, uncured prosthesis;

each layer of the prosthesis being formed by an ink-jet printer jetting the polymerizable material into a layer of the particulate powder so that the particulate bonds in selected areas;

b. placing the prosthesis in the mouth of a patient and shaping the prosthesis over a targeted area by applying sufficient pressure;

c. removing the shaped prosthesis from the mouth;

d. irradiating the prosthesis with curing light so that the prosthesis fully cures and hardens.

14. The method of claim 13, wherein the polymerizable material comprises a polymerizable acrylic compound and polymerization initiation system capable of being activated by light.

15. The method of claim 14, wherein the polymerizable material comprises a mixture of polymerizable acrylic oligomers and monomers.

16. The method of claim 13, wherein the powder bed material comprises particulate powder having a melting point higher than the jetted wax-like polymerizable material.

17. The method of claim 16, wherein the particulate powder further comprises pigment.

18. The method of claim 17, wherein the pigment is selected from organic and inorganic pigments.

19. The method of claim 13, wherein the wax-like polymerizable material further comprises pigment.

20. The method of claim 19, wherein the pigment is selected from organic and inorganic pigments.