Systems and methods for mass customization

• US 7,245,977 B1
• Filed: 07/20/2000
• Issued: 07/17/2007
• Est. Priority Date: 07/20/2000
• Status: Expired due to Term

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Simkins, Barry A.
• Primary Examiner(s): Bahta; Kidest
• Application Number:
  US09/620,253
• Time in Patent Office: 2,553 Days
• Field of Search: 700/161, 700/162, 700/98, 700/118, 700/182, 700/188, 700/173, 700/190, 700/68, 700/97, 700/163, 700/180, 700/184, 700/120, 700/119, 433/172, 433/2, 433/24, 433/212, 433/213, 433/20.1, 433/219, 600/300, 703/11, 164/34, 164/41, 246 16- 17
• US Class Current: 700/98
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 7/00 Orthodontics, i.e. obtaining or maintaining the desired position of teeth, e.g. by straightening, evening, regulating, separating, or by correcting malocclusions
• CPC Class Codes: A61C 7/002 Orthodontic computer assisted systems
• CPC Class Codes: A61C 9/004 Means or methods for taking digitized impressions
• CPC Class Codes: A61C 9/0046 Data acquisition means or methods
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/35112 Define object with spline, convert to raster, mosaic of points to make object
• CPC Class Codes: G05B 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/45167 Dentist, dental manufacture

Abstract

A method facilitates mass customization of an object by generating a template representing data common to the object; generating specific data to customize the object in conjunction with the template; and fabricating a customized version of the object.

Claims

1. A method for facilitating mass customization of an object, the object comprising a dental appliance, the method comprising:

generating a template representing data common to a plurality of different dental appliances, the template comprising a source spline;

generating specific data to customize an appliance in conjunction with the template, the specific data comprising a target spline;

wherein the source spline and the target spline define at least one tool path; and

directing at least one tool along the at least one tool path to fabricate a customized version of the appliance.

2. The method of claim 1, wherein the tool path is represented as a spline.

3. The method of claim 1, wherein the object has an ideal model surface, wherein generating the specific data comprises creating an idealized tool path from the ideal model surface.

4. The method of claim 3, further comprising generating a mathematically smooth 3D spline using the idealized tool path.

5. The method of claim 4, further comprising generating surface normals from the ideal model surface at points distributed around the idealized tool path.

6. The method of claim 5, further comprising displacing each surface normal from its end to a nearest point on the smooth 3D spline.

7. The method of claim 6, further comprising creating a spline connecting each unattached end of each surface normal.

8. The method of claim 7, wherein the ends are attached sequentially in a loop.

9. The method of claim 1, wherein directing the tool comprises using a source spline to define motion of the tool by defining tool orientation vectors.

10. The method of claim 9, further comprising adjusting the source spline.

11. The method of claim 10, wherein the source spline is adjusted by moderately elevating or lowering an angle of a surface normal.

24. The method of claim 1, wherein the dental appliance comprises cavities shaped to receive and resiliently reposition a patient'"'"'s teeth.

12. A method for fabricating a customized object, the method comprising:

receiving a digital representation of a target path;

generating a mathematically smoothed version of the target path;

applying the smoothed target path to generate a secondary target path;

generating a streamlined tool path, based on the secondary target path; and

directing a tool along the tool path to fabricate the customized object, the customized object comprising a customized dental appliance having cavities shaped to receive and resiliently reposition a patient'"'"'s teeth.

13. The method of claim 12, wherein the target path is represented as a spline.

14. The method of claim 12, wherein the object has an ideal model surface, further comprising creating an idealized tool path from the ideal model surface.

15. The method of claim 14, further comprising generating a mathematically smooth 3D spline using the idealized tool path.

16. The method of claim 15, further comprising generating surface normals from the ideal model surface at points distributed around the idealized tool path.

17. The method of claim 16, further comprising displacing each surface normal from its end to a nearest point on the smooth 3D spline.

18. The method of claim 17, further comprising creating a spline that connects each unattached end of each surface normal and wherein the ends are attached sequentially in a loop.

19. The method of claim 12, wherein directing the tool along the tool path comprises using a source spline to define motion of the tool by defining tool orientation vectors.

20. The method of claim 19, further comprising adjusting the source spline moderately elevating or lowering an angle of a surface normal.

21. A method for facilitating mass customization of an object, the object comprising an article of manufacture, the method comprising:

generating a template representing data common to a plurality of different objects, the template comprising a source spline;

extracting the common data from a calculation process used in object fabrication;

generating specific data to customize the object in conjunction with the template, the specific data comprising a target spline;

wherein the source spline and the target spline define at least one tool path; and

directing at least one tool along the at least one tool path to fabricate a customized version of the object.

22. The method claim 21, wherein the calculation process is a CAM process.

23. The method claim 21, wherein the object is an in incremental tooth adjustment appliance.

25. The method of claim 21, wherein the article of manufacture comprises a dental appliance having cavities shaped to receive and resiliently reposition a patient'"'"'s teeth.