Systems and methods for fabricating a dental template

• US 9,204,942 B2
• Filed: 05/02/2014
• Issued: 12/08/2015
• Est. Priority Date: 02/26/2003
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Phan, Loc X., Knopp, Peter G., Kuo, Eric E., Abolfathi, Amir, Wen, Huafeng
• Primary Examiner(s): PATEL, YOGESH P
• Application Number:
  US14/268,976
• Publication Number:
  US 20140322662A1
• Time in Patent Office: 585 Days
• Field of Search: 433 6- 24, 433 72- 74, 433215-225, 433 3- 5, 298/961.1, 128859-861
• US Class Current: 1/1
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 7/002 Orthodontic computer assisted systems
• CPC Class Codes: A61C 7/146 Positioning or placement of brackets; Tools therefor
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29L 2031/753 Medical equipment; Accessories therefor bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 29/49568 Orthodontic device making

Abstract

A dental template to position an object on a patient'"'"'s tooth includes digitizing the patient'"'"'s tooth; adding virtual objects to predetermined locations on the digitized tooth; and fabricating the dental template to locate the object on the patient'"'"'s tooth. The template can be used for etching or for positioning brackets on teeth.

Claims

1. A system for positioning a plurality of orthodontic objects on a patient'"'"'s teeth, comprising:

a computer system; and

a template adapted for placement over the teeth so as to fit on and span a plurality of the patient'"'"'s teeth, the template comprising an inner teeth facing surface adapted to be positioned adjacent to the patient'"'"'s teeth and an outer surface away from the inner teeth facing surface, the inner teeth facing surface defining a plurality of teeth receiving cavities, each cavity shaped based on a digital teeth model of the patient'"'"'s teeth made using the computer system, such that each received tooth geometrically fits within one of the plurality of teeth receiving cavities;

wherein the computer system is configured with instructions to display a plurality of virtual orthodontic objects placed at specific locations and orientations on the digital teeth model, the template further comprising one or more openings, each comprising a cut-out that is open to a gingival side of the template, the cut-out defining an orthodontic object support edge shaped to allow an orthodontic object base to fit directly into the opening to position an orthodontic object in the template and wherein the template comprises a plurality of orthodontic objects placed at the specific locations and orientations of the plurality of virtual orthodontic objects on the digital teeth model.

2. A system as in claim 1, wherein the template comprises a directly fabricated articulable shell with a plurality of flexibly linked cavities.

3. A system as in claim 1, wherein the template comprises a non-articulated template fabricated directly from the digital teeth model.

4. A system as in claim 1, wherein the template is formed by a process comprising:

generating a template model based on the digital teeth model; and

generating the template based on the template model.

5. A system as in claim 1, wherein the one or more openings comprise a rounded edge for positioning of a bracket.

6. A system as in claim 1, wherein a thickness of the template is at least 0.03 inches in a buccal-lingual direction.

7. A system as in claim 1, wherein the template is made from a variable physical material having a first state for retention of the template on the patient'"'"'s teeth and a second state for facilitating removal of the template from the patient'"'"'s teeth.

8. A system as in claim 1, wherein the template is articulated.

9. A system as in claim 1, wherein the template is unified.

10. A system as in claim 1, wherein the outer surface is larger than the inner teeth facing surface by an amount, the amount within a range between about 105% to about 150% of the inner teeth facing surface.

11. A system as in claim 1, wherein the template comprises a plurality of movable template components linked together with a flexible material.

12. A system as in claim 1, wherein the template comprises a plurality of articulated segments linked together with a flexible material.