Systems and methods for fabricating a dental template

• US 9,433,479 B2
• Filed: 11/03/2015
• Issued: 09/06/2016
• 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
• Application Number:
  US14/931,681
• Publication Number:
  US 20160051342A1
• Time in Patent Office: 308 Days
• Field of Search: 433 6- 24
• 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 fabricating a template for positioning orthodontic objects on a patient'"'"'s teeth, the system comprising:

one or more processors; and

memory comprising program code that, when executed by the one or more processors, cause the system to;

receive a digital teeth model representing a patient'"'"'s teeth;

display one or more virtual orthodontic objects placed at respective locations and orientations on the digital teeth model;

determine a geometry for a template adapted for placement over the patient'"'"'s teeth and comprising one or more openings defining one or more object support edges, wherein the one or more object support edges are shaped to receive and position one or more orthodontic objects at respective locations and orientations on the patient'"'"'s teeth corresponding to the respective locations and orientations of the one or more virtual orthodontic objects on the digital teeth model, and wherein the one or more openings each comprise a cut-out open to a gingival side of the template; and

output fabrication data for fabricating the template having the determined geometry.

2. The system of claim 1, wherein the fabrication data is configured for direct fabrication of the template using a rapid prototyping method.

3. The system of claim 2, wherein the rapid prototyping method comprises fused deposition modeling, 3D printing, or stereolithography.

4. The system of claim 1, wherein the fabrication data is configured for indirect fabrication of the template using thermoforming over a mold.

5. The system of claim 1, wherein the one or more orthodontic objects comprise one or more fixed orthodontic appliances to be placed on the patient'"'"'s teeth.

6. The system of claim 1, wherein the one or more openings are each shaped to receive an orthodontic object base.

7. The system of claim 1, wherein the template comprises a plurality of teeth receiving cavities shaped based on the digital teeth model.

8. The system of claim 1, wherein the template comprises a plurality of movable template segments linked together.

9. The system of claim 1, further comprising the template fabricated with the determined geometry.

10. A method for fabricating a template for positioning orthodontic objects on a patient'"'"'s teeth, the method comprising:

receiving, with aid of a processor, a digital teeth model representing a patient'"'"'s teeth;

displaying, with aid of the processor, one or more virtual orthodontic objects placed at respective locations and orientations on the digital teeth model;

determining, with aid of the processor, a geometry for a template adapted for placement over the patient'"'"'s teeth and comprising one or more openings defining one or more object support edges, wherein the one or more object support edges are shaped to receive and position one or more orthodontic objects at respective locations and orientations on the patient'"'"'s teeth corresponding to the respective locations and orientations of the one or more virtual orthodontic objects on the digital teeth model, and wherein the one or more openings each comprise a cut-out open to a gingival side of the template; and

outputting, with aid of the processor, fabrication data for fabricating the template having the determined geometry.

11. The method of claim 10, wherein the fabrication data is configured for direct fabrication of the template using a rapid prototyping method.

12. The method of claim 11, wherein the rapid prototyping method comprises fused deposition modeling, 3D printing, or stereolithography.

13. The method of claim 10, wherein the fabrication data is configured for indirect fabrication of the template using thermoforming over a mold.

14. The method of claim 10, wherein the one or more orthodontic objects comprise one or more fixed orthodontic appliances to be placed on the patient'"'"'s teeth.

15. The method of claim 10, wherein the one or more openings are each shaped to receive an orthodontic object base.

16. The method of claim 10, wherein the template comprises a plurality of teeth receiving cavities shaped based on the digital teeth model.

17. The method of claim 10, wherein the template comprises a plurality of movable template segments linked together.