METHOD OF MAKING A SURGICAL TEMPLATE USED FOR A COMPUTER-GUIDED DENTAL IMPLANT SURGERY

• US 20100240000A1
• Filed: 02/26/2010
• Published: 09/23/2010
• Est. Priority Date: 03/19/2009
• Status: Active Grant

• Current Assignee: Pou Yuen Technology Co. Ltd. (POU CHEN Corporation)
• Original Assignee: Pou Yuen Technology Co. Ltd. (POU CHEN Corporation)
• Inventors: Kuo, Chuan-Chu, Chen, Jiun-Ren, Chen, Chien-An, Chen, Ying-Li, YAU, Hong-Tzong, Yang, Chun-Chun
• Granted Patent: US 8,135,492 B2
• Time in Patent Office: Days
• US Class Current: 433/37
• CPC Class Codes: A61C 1/084 of implanting tools
• CPC Class Codes: A61C 13/0003 Making bridge-work, inlays, implants or the like
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture

Abstract

A method of making a surgical template used for a computer-guided dental implant surgery includes the steps of: establishing implant planning data of a patient'"'"'s jaw, producing a digital plaster model of the patient'"'"'s jaw, allowing the digital plaster model to have the implant planning data, integrating the digital plaster model with the implant planning data to obtain a digital machining data, holding and machining a modeling block at a machining position according to the digital machining data to form a solid jaw model corresponding to the patient'"'"'s jaw and having teeth, gums, and at least one implant-position indicating structure, mounting a positioning member at the implant-position indicating structure, and producing a negative template body from an assembly of the solid jaw model and the positioning member with a thermoplastic dental material by a molding process or a vacuum forming process.

Claims

1. A method of making a surgical template used for a computer-guided dental implant surgery, comprising the steps of:

(a) producing a three-dimensional model by a CT scanning performed on a patient'"'"'s jaw and establishing corresponding implant planning data to obtain a digital model of an assembly of the patient'"'"'s jaw and the implant planning data;

(b) making a negative model by direct impression modeling of the patient'"'"'s jaw, and then a positive plaster model from the negative model, and producing a digital plaster model corresponding to the positive plaster model;

(c) positioning the digital model of the assembly of the patient'"'"'s jaw and the implant planning data relative to the digital plaster model to allow the digital plaster model to have the implant planning data;

(d) integrating the digital plaster model with the implant planning data to obtain a digital machining data;

(e) holding and machining a modeling block at a machining position by a machine according to the digital machining data to form a solid jaw model corresponding to the patient'"'"'s jaw and having teeth, gums, and at least one implant-position indicating structure;

(f) mounting a positioning member at the implant-position indicating structure; and

(g) producing a negative template body from an assembly of the solid jaw model and the positioning member with a thermoplastic dental material by one of a molding process and a vacuum forming process such that the negative template body has a lower surface complementary to the assembly of the solid jaw model and the positioning member, and at least one implant guide hole formed therethrough at a position corresponding to the implant-position indicating structure;

whereby, the surgical template includes the negative template body.

2. The method as claimed in claim 1, wherein, in said step (e), the machine is a five-axis CNC machine.

3. The method as claimed in claim 1, wherein, in said step (e), the modeling block is made of one of plaster and a wood substitute material.

4. The method as claimed in claim 1, wherein, in said step (d), the digital machining data includes a plaster model and at least one implant-position indicating unit.

5. The method as claimed in claim 4, wherein, in said step (d), the implant-position indicating unit is configured as one of a pinhole formed in the plaster model of the machining data, and a pin extending from the plaster model of the machining data.

6. The method as claimed in claim 5, wherein, in said step (g), the negative template body is produced by the molding process, the molding process including the substeps of:

(1) coating the assembly of the solid jaw model and the positioning member with a thermoplastic first coating material such that an outer surface of the first coating material is aligned with an end surface of the positioning member;

(2) coating the first coating material with a second coating material having a melting point higher than that of the first coating material;

(3) heating the first and second coating materials to a temperature between the melting points of said first and second coating materials so as to melt only the first coating material, thereby forming a mold cavity such that the solid jaw model, the positioning member, and the second coating material constitute cooperatively a mold;

(4) heating and pouring the dental material into the mold cavity;

(5) allowing the dental material to cure to thereby form the negative template body; and

(6) removing the second coating material and the solid jaw model from the negative template body.

7. The method as claimed in claim 6, wherein, in said step (g), said molding process further includes a substep (7) of, after said substep (6), grinding and polishing the negative template body.

8. The method as claimed in claim 6, wherein:

in said step (d), the implant-position indicating unit is configured as the pin extending from the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pin extending from the solid jaw model; and

in said step (f), the positioning member is configured as a sleeve that is sleeved on the pin extending from the solid jaw model so that, in said step (g), when the negative template body is formed, the sleeve is embedded within the negative template body;

whereby, the surgical template further includes the sleeve.

9. The method as claimed in claim 5, wherein, in said step (g), the negative template body is produced by the molding process, the molding process including the substeps of:

(1) coating the assembly of the solid jaw model and the positioning member with a thermoplastic first coating material such that an outer surface of the first coating material is aligned with an end surface of the positioning member;

(2) coating the first coating material with a second coating material having a melting point higher than that of the first coating material;

(3) heating the first and second coating materials to a temperature between the melting points of said first and second coating materials so as to melt only the first coating material, thereby forming a mold cavity such that the solid jaw model, the positioning member, and the second coating material constitute cooperatively a mold;

(4) heating and pouring the dental material into the mold cavity;

(5) allowing the dental material to cure to thereby form the negative template body; and

(6) removing the second coating material, said positioning member, and the solid jaw model from the negative template body.

10. The method as claimed in claim 9, wherein, in said step (g), said molding process further includes a substep (7) of, after said substep (6), grinding and polishing the negative template body.

11. The method as claimed in claim 9, wherein:

in said step (d), the implant-position indicating unit is configured as the pinhole formed in the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pinhole formed in the solid jaw model; and

in said step (f), the positioning member is configured as a pin having a pin body inserted into the pinhole in the solid jaw model, and a head exposed outwardly of the pinhole in the solid jaw model and spaced apart from the pinhole in the solid jaw model by a predetermined distance so that, in said step (g), when the negative template body is formed, and when the positioning member is removed from the negative template body, an implant guide hole is formed in the negative template body.

12. The method as claimed in claim 11, after said step (g), further comprising a step (h) of inserting a sleeve into the implant guide hole in the negative plate body, the sleeve having a sleeve body disposed within the implant guide hole, and a flange extending radially and outwardly from an end of the sleeve body and abutting against an outer surface of the negative template body;

whereby, the surgical template further includes the sleeve.

13. The method as claimed in claim 5, wherein, in said step (g), the negative template body is produced by the molding process, the molding process including the substeps of:

(1) coating the assembly of the solid jaw model and the positioning member with a thermoplastic first coating material such that an outer surface of the first coating material is aligned with an end surface of the positioning member;

(2) coating the first coating material with a second coating material having a melting point higher than that of the first coating material;

(3) heating the first and second coating materials to a temperature between the melting points of said first and second coating materials so as to melt only the first coating material, thereby forming a mold cavity such that the solid jaw model, the positioning member, and the second coating material constitute cooperatively a mold;

(4) heating and pouring the dental material into the mold cavity;

(5) allowing the dental material to cure to thereby form the negative template body; and

(6) removing the second coating material and the solid jaw model from the negative template body.

14. The method as claimed in claim 13, wherein, in said step (g), said molding process further includes a substep (7) of, after said substep (6), grinding and polishing the negative template body.

15. The method as claimed in claim 13, wherein:

in said step (d), the implant-position indicating unit is configured as the pinhole formed in the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pinhole formed in the solid jaw model;

in said step (f), a portion of the positioning member is inserted into the pinhole formed in the solid jaw model, and includes a pin constituting the portion of the positioning member, and a sleeve that is sleeved on the pin; and

in said substep (6) of said step (g), when the second coating material and the pin are removed from the negative template body, the sleeve is embedded within the dental material;

whereby, the surgical template further includes the sleeve.

16. The method as claimed in claim 5, wherein, in said step (g), the negative template body is produced by the vacuum forming process, the vacuum forming process including the substeps of:

(1) preparing a plastic sheet made of the dental material;

(2) heating and softening the plastic sheet;

(3) placing the softened plastic sheet on the solid jaw model and the positioning member;

(4) applying a vacuum to the softened plastic sheet to allow the softened plastic sheet to deform so that a side surface of the softened plastic sheet is complementary in structure to an assembly of the solid jaw model and the positioning member;

(5) hardening the deformed plastic sheet;

(6) trimming the hardened plastic sheet; and

(7) removing the solid jaw model and the positioning member from the trimmed plastic sheet.

17. The method as claimed in claim 16, wherein, in said step (g), the vacuum forming process further includes a step (8) of, after said substep (7), grinding and polishing the trimmed plastic sheet.

18. The method as claimed in claim 16, wherein:

in said step (d), the implant-position indicating unit is configured as the pin extending from the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pin extending from the solid jaw model; and

in said step (f), the positioning member is configured as a sleeve that is sleeved on the pin extending from the solid jaw model so that, in said step (g), when the negative template body is formed, the sleeve is embedded within the negative template body;

whereby, the surgical template further includes the sleeve.

19. The method as claimed in claim 16, wherein:

in said step (d), the implant-position indicating unit is configured as the pinhole formed in the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pinhole formed in the solid jaw model; and

in said step (f), the positioning member is configured as a pin having a pin body inserted into the pinhole in the solid jaw model, and a head exposed outwardly of the pinhole in the solid jaw model and spaced apart from the pinhole in the solid jaw model by a predetermined distance so that, in said step (g), when the negative template body is formed, and when the positioning member is removed from the negative template body, an implant guide hole is formed in the negative template body.

20. The method as claimed in claim 16, after said step (g), further comprising a step (h) of inserting a sleeve into the implant guide hole in the negative plate body, the sleeve having a sleeve body disposed within the implant guide hole, and a flange extending radially and outwardly from an end of the sleeve body and abutting against an outer surface of the negative template body;

whereby, the surgical template further includes the sleeve.

21. The method as claimed in claim 16, wherein:

in said step (d), the implant-position indicating unit is configured as the pinhole formed in the plaster model of the machining data so that, in said step (e), the implant-position indicating structure is configured as a pinhole formed in the solid jaw model;

in said step (f), the positioning member is inserted into the pinhole formed in the solid jaw model, and is configured as a pin and a sleeve that is sleeved on the pin; and

in said substep (7) of said step (g), after the solid jaw model and the positioning member are removed from the trimmed plastic sheet, the sleeve is embedded within the plastic sheet.

22. A method of making a surgical template used for a computer-guided dental implant surgery, comprising the steps of:

(a) producing a three-dimensional model by a CT scanning performed on a patient'"'"'s jaw and establishing corresponding implant planning data to obtain a digital model of an assembly of the patient'"'"'s jaw and the implant planning data;

(b) making a negative model by direct impression modeling of the patient'"'"'s jaw, and then a positive plaster model from the negative model, and producing a digital plaster model corresponding to the positive plaster model;

(c) positioning the digital model of the assembly of the patient'"'"'s jaw and the implant planning data relative to the digital plaster model to allow the digital plaster model to have the implant planning data;

(d) integrating the digital plaster model with the implant planning data to obtain a digital machining data, the digital machining data including a plaster model and at least one implant-position indicating unit configured as a pin extending from the plaster model;

(e) holding and machining a modeling block at a machining position by a machine according to the digital machining data to form a solid jaw model corresponding to the patient'"'"'s jaw and having teeth, gums, and at least one implant-position indicating structure configured as a pin extending from the solid jaw model; and

(f) producing a negative template body from the solid jaw model with a thermoplastic dental material by one of a molding process and a vacuum forming process such that the negative template body has a lower surface complementary to the solid jaw model, and at least one implant guide hole formed therethrough at a position corresponding to the implant-position indicating structure;

whereby, the surgical template includes the negative template body.

23. The method as claimed in claim 22, after said step (e), further comprising a step (g) of inserting a sleeve into the implant guide hole in the negative plate body, the sleeve having a sleeve body disposed within the implant guide hole, and a flange extending radially and outwardly from an end of the sleeve body and abutting against an outer surface of the negative template body;

whereby, the surgical template further includes the sleeve.

24. The method as claimed in claim 22, wherein, in said step (e), the modeling block is made of one of plaster and a wood substitute material.