Method and system for designing and producing dental prostheses and appliances

• US 9,539,071 B2
• Filed: 10/23/2013
• Issued: 01/10/2017
• Est. Priority Date: 02/24/2004
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Taub, Eldad, Kopelman, Avi
• Primary Examiner(s): SHECHTMAN, SEAN P
• Application Number:
  US14/061,598
• Publication Number:
  US 20140142736A1
• Time in Patent Office: 1,175 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: A61C 13/0006 Production methods
• CPC Class Codes: A61C 13/09 Composite teeth, e.g. front and back section A61C13/0835, A61C13/1023 take precedence; Multilayer teeth
• CPC Class Codes: A61C 13/34 Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins [4]
• CPC Class Codes: A61C 5/73 Composite crowns
• CPC Class Codes: A61C 5/77 Methods or devices for making crowns
• CPC Class Codes: A61C 7/002 Orthodontic computer assisted systems
• CPC Class Codes: A61C 8/0048 Connecting the upper structure to the implant, e.g. bridging bars A61C8/0028 takes precedence
• CPC Class Codes: A61C 9/0053 Optical means or methods, e.g. scanning the teeth by a laser or light beam
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 19/0421 Multiprocessor system
• CPC Class Codes: G16H 20/40 relating to mechanical, radiation or invasive therapies, e.g. surgery, laser therapy, dialysis or acupuncture
• CPC Class Codes: Y10T 29/49567 Dental appliance making

Abstract

A virtual model of an intraoral cavity is provided, wherein this process is initialized by a dental clinic, and the design and manufacture of a suitable dental prosthesis for the intraoral cavity is shared between a dental lab and a service center.

Claims

1. A method for manufacturing a dental prosthesis, the method comprising:

receiving three dimensional data indicative of a patient'"'"'s oral cavity;

generating, based on the three dimensional data, a dentition model that includes a prosthesis preparation and external surface shape geometry of a prosthesis coupling portion of the preparation;

generating, based on the dentition model, prosthesis data comprising three dimensional shape data of a first portion of the dental prosthesis, the first portion being an internal part of the dental prosthesis and including an inner surface of the dental prosthesis, the three dimensional shape data of the first portion including a preparation coupling portion of the dental prosthesis that is configured for coupling the first portion of the dental prosthesis and the preparation, the prosthesis data further comprising three dimensional shape data of an outer surface of the first portion of the dental prosthesis;

fabricating the first portion of the dental prosthesis based on the prosthesis data; and

transmitting data for manufacture of a second portion of the dental prosthesis, the second portion being configured to couple with the first portion, the transmitted data including at least one of;

     1) three dimensional shape data of the outer surface of the first portion, and

     2) three dimensional shape data of an inner surface of the second portion that is configured for coupling the second portion and the first portion.

2. The method of claim 1, wherein a dimensional accuracy used for fabricating the inner surface of the first portion is equal to or less than about 40 microns.

3. The method of claim 1, wherein a dimensional accuracy used for fabricating the inner and outer surfaces of the first portion is equal to or less than about 40 microns.

4. The method of claim 1, wherein the first portion comprises a prosthesis coping.

5. The method of claim 1, wherein the three dimensional data indicative of a patient'"'"'s oral cavity is received over an electronic communication network.

6. The method of claim 1, wherein the data for manufacture of the second portion is transmitted over an electronic communication network to a dental service lab.

7. The method of claim 1, wherein the generated prosthesis data comprises three dimensional shape data of the inner surface and an outer surface of the second portion of the dental prosthesis.

8. The method of claim 1, wherein the three dimensional data indicative of a patient'"'"'s oral cavity is generated at a dental clinic.

9. A method for manufacturing a dental prosthesis, the method comprising:

receiving three dimensional data indicative of a patient'"'"'s oral cavity;

generating, based on the three dimensional data, a dentition model that includes a prosthesis preparation and external surface shape geometry of a prosthesis coupling portion of the preparation;

generating, based on the dentition model, first portion prosthesis data comprising three dimensional shape data of a first portion of the dental prosthesis, the first portion being an internal part of the dental prosthesis and including an inner surface of the dental prosthesis, the first portion prosthesis data including three dimensional shape data of a preparation coupling portion of the dental prosthesis that is configured for coupling the first portion of the dental prosthesis and the preparation, the first portion prosthesis data further comprising three dimensional shape data of an outer surface of the first portion of the dental prosthesis;

transmitting the first portion prosthesis data to a dental service center for manufacture of the first portion of the dental prosthesis; and

fabricating a second portion of the dental prosthesis, the second portion being an external part of the dental prosthesis and having an external surface of the dental prosthesis, the second portion of the dental prosthesis being configured to couple with the first portion of the dental prosthesis.

10. The method of claim 9, wherein a dimensional accuracy used for fabricating the inner surface of the first portion is equal to or less than about 40 microns.

11. The method of claim 9, wherein a dimensional accuracy used for fabricating the inner and outer surfaces of the first portion is equal to or less than about 40 microns.

12. The method of claim 9, wherein the first portion comprises a prosthesis coping.

13. The method of claim 9, wherein the three dimensional data indicative of a patient'"'"'s oral cavity is received over an electronic communication network.

14. The method of claim 9, wherein the prosthesis data for manufacture of the second portion is transmitted over an electronic communication network to a dental service lab.

15. The method of claim 9, wherein the generated prosthesis data comprises three dimensional shape data of the inner surface and an outer surface of the second portion of the dental prosthesis.

16. The method of claim 9, wherein the three dimensional data indicative of a patient'"'"'s oral cavity is generated at a dental clinic.

17. The method of claim 9, wherein fabricating the second portion of the dental prosthesis comprises:

receiving the first portion of the dental prosthesis; and

applying a first material layer directly to the first portion.

18. The method of claim 17, further comprising:

obtaining three dimensional shape data of an as-applied external surface of the first material layer; and

using the three dimensional shape data of the first material layer as-applied external surface to generate first machining paths for a material removal operation configured to produce a predefined desired external surface of the first material layer, the first machining paths being tailored to the first material layer as-applied external surface to reduce machining times as compared to comparable machining paths suitable for a fictitious external surface envelope for the first material layer.

19. The method of claim 18, further comprising:

applying a second material layer directly to the first material layer;

obtaining three dimensional shape data of an as-applied external surface of the second material layer; and

using the three dimensional shape data of the second material layer as-applied external surface to generate second machining paths for a material removal operation configured to produce a predefined desired external surface of the second material layer, the second machining paths being tailored to the second material layer as-applied external surface to reduce machining times as compared to comparable machining paths suitable for a fictitious external surface envelope for the second material layer.

20. The method of claim 9, wherein fabricating the second portion of the dental prosthesis comprises:

receiving the first portion of the dental prosthesis;

mounting the first portion to a holding fixture;

scanning the inner surface of the first portion to generate three dimensional surface data of the first portion inner surface;

applying a first material layer directly to the first portion;

using the three dimensional surface data of the first portion inner surface to adjust material removal instructions used to form an external surface of the first material layer to produce a desired alignment between the first material layer external surface and the first portion inner surface.