Methods, systems and accessories useful for procedures relating to dental implants

• US 9,782,238 B2
• Filed: 04/25/2016
• Issued: 10/10/2017
• Est. Priority Date: 07/17/2008
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Kopelman, Avi
• Primary Examiner(s): EIDE, HEIDI MARIE
• Application Number:
  US15/138,034
• Publication Number:
  US 20160235506A1
• Time in Patent Office: 533 Days
• CPC Class Codes: A61C 13/0004 Computer-assisted sizing or machining of dental prostheses
• CPC Class Codes: A61C 13/0022 Blanks or green, unfinished dental restoration parts
• CPC Class Codes: A61C 13/34 Making or working of models, e.g. preliminary castings, trial dentures; Dowel pins [4]
• CPC Class Codes: A61C 8/00 Means to be fixed to the jaw-bone for consolidating natural teeth or for fixing dental prostheses thereon; Dental implants; Implanting tools fastening of peg-teeth in the mouth A61C13/30
• CPC Class Codes: A61C 8/0001 Impression means for implants, e.g. impression coping
• CPC Class Codes: A61C 9/00 Impression cups, i.e. impression trays; Impression methods computer-assisted sizing A61C13/0004; instruments for determining occlusion A61C19/05
• CPC Class Codes: A61C 9/002 Means or methods for correctly replacing a dental model, e.g. dowel pins; Dowel pin positioning means or methods
• CPC Class Codes: A61C 9/0053 Optical means or methods, e.g. scanning the teeth by a laser or light beam

Abstract

A method and system are provided for manufacturing a physical dental model. A virtual model is provided representative of at least a portion of the intra-oral cavity including at least one dental implant implanted therein, and the virtual model includes a virtual portion representative of each dental implant. The virtual spatial disposition of each such virtual portion is determined with respect to the virtual model, corresponding to a real spatial disposition of the respective implant with respect to the intra oral cavity. A physical model is then manufactured based on the virtual model, the physical model including a physical analog corresponding to each implant at a respective physical spatial disposition with respect to the physical model corresponding to the respective virtual spatial disposition of the respective virtual portion with respect to the first virtual model as already determined. In some embodiments, a jig is provided configured for maintaining a desired physical spatial disposition between the physical analog and a cavity of the physical dental model at least until the physical analog is affixed in the cavity.

Claims

1. A system for manufacturing a physical dental model of an intra-oral cavity, comprising:

a computer system configured for providing a first virtual model representative of at least a part of the intra-oral cavity including at least one dental implant implanted therein, said first virtual model comprising a virtual portion representative of a respective physical portion of a said at least one dental implant, said virtual portion being at a virtual spatial disposition with respect to said first virtual model, and for providing an implant spatial disposition of the said at least one dental implant with respect to said part of the intra oral cavity based on said virtual spatial disposition;

a physical analog corresponding to said at least one dental implant; and

a manufacturing system configured for manufacturing the physical dental model, corresponding to said part of the intra-oral cavity, based on said first virtual model, said physical dental model including a physical analog corresponding to said at least one dental implant, said physical analog being at an analog spatial disposition with respect to said physical dental model corresponding to said implant spatial disposition of said at least one dental implant with respect to said part of the intra oral cavity provided by said computer system, the manufacturing system configured for manufacturing the physical analog embedded in a jacket structure by applying a layer of material on the physical analog and machining the layer of material such that the jacket structure is shaped to removably couple to a cavity structure formed in the physical dental model.

2. The system according to claim 1, further comprising scanning apparatus configured for providing surface data to said computer system for providing said first virtual model.

3. The system according to claim 1, wherein said manufacturing system is computer controlled.

4. The system according to claim 1, wherein said manufacturing system is configured for manufacturing said physical dental model via a material removal operation applied to a blank of material.

5. The system according to claim 1, wherein said manufacturing system is configured for manufacturing said physical dental model via a CNC machining operation applied to a blank of material.

6. The system according to claim 1, wherein said manufacturing system is configured for manufacturing said physical dental model via a rapid prototyping process.

7. The system according to claim 1, wherein:

said computer system is configured to provide a second virtual model at least partially representative of said physical analog, and generate a third virtual model including a virtual cavity configured for virtually accommodating the second virtual model therein; and

wherein said manufacturing system is configured to manufacture said physical dental model further based on said third virtual model.

8. The system according to claim 7, wherein said computer system is configured to generate said third virtual model by manipulating said second virtual model into an aligned virtual spatial disposition consistent with the said virtual spatial disposition and corresponding to said implant spatial disposition of the respective dental implant with respect to said part of the intra oral cavity.

9. The system according to claim 7, wherein said manufacturing system is configured to form an outer physical dental model surface corresponding to dental surfaces of said part of the intra oral cavity, and to form a physical recess in said physical dental model for accommodating said physical analog at said analog spatial disposition, said physical recess corresponding to said virtual cavity.

10. The system according to claim 9, wherein said virtual cavity has a virtual form corresponding to a physical form that is complementary to that of the respective said physical analog, such that said physical recess formed in said physical dental model provides a fit with respect to said physical analog to accommodate the respective said physical analog therein at said analog spatial disposition.