System to manufacture custom orthodontic appliances, program product, and related methods

Abstract

A system to manufacture orthodontic appliances, program product, and associated methods are provided. An embodiment of a system can include a virtual orthodontic appliance design computer having orthodontic appliance design program product provided to design a virtual dimensional representation of an orthodontic appliance including bracket bodies and bracket pads, and a mold apparatus positioned to form each bracket body and bracket pad. The system also includes a data processing computer including computer-aided manufacturing program product provided to derive electrical discharge device control instructions including a virtual dimensional representation of a bracket slot in the bracket, and an electrical discharge machining apparatus. The electrical discharge machining apparatus can include a controller including control program product to derive a control signal carrying the electrical discharge device control instructions and an electrical discharge device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and benefits of the invention, as well as others which will become apparent, may be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope since it may include other effective embodiments as well.

FIG. 1 is a schematic block diagram of a system to manufacture orthodontic appliances according to an embodiment of the present invention;

FIG. 2 is a schematic diagram of a process flow to manufacture orthodontic appliances according to an embodiment of the present invention;

FIG. 3 is a perspective view of an orthodontic appliance according to an embodiment of the present invention;

FIG. 4 is a perspective view of a bracket of an orthodontic appliance according to an embodiment of the present invention;

FIG. 5 is a perspective view of a bracket of an orthodontic appliance according to an embodiment of the present invention;

FIG. 6 is a perspective view of a bracket slot of a bracket of an orthodontic appliance according to an embodiment of the present invention;

FIG. 7 is a perspective view of a bracket slot of a bracket of an orthodontic appliance according to an embodiment of the present invention;

FIG. 8 is a perspective view of a mold-forming apparatus according to an embodiment of the present invention;

FIG. 9 is a perspective view of a mold tree according to an embodiment of the present invention;

FIG. 10 is a perspective view of an electrical discharge apparatus according to an embodiment of the present invention;

FIG. 11 is a perspective view of an electrical discharge apparatus according to an embodiment of the present invention;

FIG. 12 is a flow diagram of a method of manufacturing an orthodontic appliance according to an embodiment of the present invention;

FIG. 13 is a flow diagram of a method of manufacturing an orthodontic appliance according to an embodiment of the present invention;

FIG. 14 is a perspective view of a bracket of an orthodontic appliance according to an embodiment of the present invention;

FIGS. 15-19 are perspective views of a portion of a molding apparatus and a molded bracket of an orthodontic appliance according to an embodiment of the present invention;

FIG. 20 is a flow diagram of a method of manufacturing an orthodontic appliance according to an embodiment of the present invention;

FIG. 21 is a perspective view of a bracket of an orthodontic appliance overlaid with a bracket slot cutting pattern according to an embodiment of the present invention;

FIG. 22 is a schematic diagram of a bracket of an orthodontic appliance overlaid with a bracket slot cutting pattern according to an embodiment of the present invention;

FIG. 23 is a sequence of numerical code in ASCII format provided to execute to an electrical discharge cutting pattern illustrated in FIG. 22 according to an embodiment of the present invention;

FIG. 24 is block flow diagram of a method of manufacturing and orthodontic appliance according to an embodiment of the present invention;

FIG. 25 is a perspective view of a bracket of an orthodontic appliance overlaid with a bracket slot cutting pattern according to an embodiment of the present invention;

FIG. 26 is a schematic diagram of a bracket of an orthodontic appliance overlaid with a bracket slot cutting pattern according to an embodiment of the present invention; and

FIG. 27 is a sequence of numerical code in ASCII format provided to execute to an electrical discharge cutting pattern illustrated in FIG. 26 according to an embodiment of the present invention.

Claims

1. A system to manufacture orthodontic appliances, the system comprising: a virtual orthodontic appliance design computer having a processor, memory coupled to the processor, and orthodontic appliance design program product stored in the memory including instructions to perform the operations of receiving patient dentition data and designing a virtual dimensional representation of an orthodontic appliance defining virtual orthodontic appliance design data responsive to the received patient dentition data, the orthodontic appliance including a customized archwire and a plurality of precision customized brackets each including a tooth facing bonding surface, and a bracket slot;a mold forming apparatus positioned to form each bracket including a mold positioned to receive a bracket-forming material and a dispensing device positioned to dispense the bracket-forming material into the mold, the mold having a cavity for each of the plurality of brackets defining peripheries of the bracket when the bracket-forming material is positioned therein and having a channel defining peripheries of a runner when filled with the bracket-forming material, each molded bracket connected to the runner when removed from the mold;a data processing computer in communication with the virtual orthodontic appliance design computer and having memory and computer-aided manufacturing program product stored in the memory including instructions to perform the operation of deriving electrical discharge device control instructions including those to perform the operation of forming a pattern describing a virtual dimensional representation of the bracket slot responsive to the virtual orthodontic appliance design data; andan electrical discharge machining apparatus in communication with the data processing computer and comprising: a controller having memory and data communication program product stored in the memory including instructions to perform the operation of receiving the electrical discharge device control instructions and control program product also stored in the memory and including instructions to derive a control signal carrying the electrical discharge device control instructions responsive to the received electrical discharge device control instructions, andan electrical discharge device comprising an electrical discharge electrode assembly including an electrode and at least one drive section adapted to position each bracket in electrical discharge contact with the electrode to form the bracket slot and adapted to simultaneously separate the bracket from the runner when forming the bracket slot responsive to the control signal.

2. A system as defined in claim 1, wherein the electrical discharge device control instructions include those to perform the operation of executing an electrical discharge cutting pattern extending along a perimeter of the bracket slot.

3. A system as defined in claim 2, wherein the bracket slot includes an open surface end and a closed base end and two spaced-apart sides extending therebetween, and wherein an initial portion of the cutting pattern extends along a portion of an outer surface of the bracket substantially transverse to at least one of the sides.

4. A system as defined in claim 2, wherein the bracket slot includes an open surface end and a closed base end and two spaced-apart sides extending therebetween, wherein the bracket includes a bracket wing having slot-side surface, and wherein a portion of the cutting pattern extends along the slot-side surface of the bracket wing to thereby form the slot-side surface of the bracket wing.

5. A system as defined in claim 2, wherein the bracket slot includes an open end and a closed base end and two spaced-apart sides extending therebetween, and wherein the cutting pattern includes a transverse extension extending into the bracket from one of the spaced-apart sides at the base end of the bracket slot to thereby define a bracket slot undercut.

6. A system as defined in claim 2, wherein the bracket slot includes an open end and a closed base end and two spaced-apart sides extending therebetween spaced apart to define a bracket slot width, and wherein the cutting pattern includes at least one transverse extension extending into the bracket from a corresponding at least one of the spaced-apart sides adjacent the base to thereby define a bracket slot undercut having an undercut width, the undercut width exceeding the slot width.

7. A system as defined in claim 2, wherein the electrical discharge device control instructions include those to perform the operation of detecting a position on a bracket defining a cutting pattern starting point to begin electrical discharge machining.

8. A system as defined in claim 2, wherein the electrode includes a traveling wire electrical discharge electrode defining a traveling wire electrode, wherein the electrode assembly includes a supply reel containing unused portions of the traveling wire electrode to provide a continuous stream of supply traveling wire electrode when executing the cutting pattern and a take-up reel containing used portions of the traveling wire electrode to collect the traveling wire electrode supplied from the supply reel when executing the cutting pattern to form the bracket slot and to provide tension to the traveling wire electrode to thereby provide a substantially planer cutting surface, wherein the bracket slot and the archwire form a bracket slot-archwire interface when the archwire is positioned within the bracket slot, and wherein the bracket slot-archwire interface provides in at least one dimension a tolerance of equal to or less than approximately 20 microns.

9. A system as defined in claim 2, wherein the electrode includes a die-sinker-electrical discharge electrode, wherein the electrode assembly includes a ram to extend the electrode adjacent the bracket when executing the cutting pattern to form the bracket slot, and wherein the bracket slot is specified having at least in one dimension a tolerance of less than 30 microns.

10. A system to manufacture orthodontic appliances, the system comprising: a numerical control data processor defining a controller having memory and control program product stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of deriving a numerical control signal carrying electrical discharge device control instructions to form a bracket slot in a bracket of an orthodontic appliance and to separate the bracket from a runner connected to the bracket; andan electrical discharge device in communication with the controller and having an electrical discharge electrode assembly including an electrode and having at least one drive section adapted to position the bracket in electrical discharge contact with the electrode responsive to the numerical control signal to form the bracket slot and to separate the bracket from the runner when forming the bracket slot.

11. A system to manufacture orthodontic appliances, the system comprising: a controller having memory, data communication program product stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of receiving electrical discharge device control instructions describing a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance, and control program product also stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of deriving a control signal carrying the electrical discharge device control instructions responsive to the electrical discharge device control instructions; andan electrical discharge device in communication with the controller having an electrical discharge electrode assembly including an electrode and having at least one drive section adapted to position the bracket in electrical discharge contact with the electrode responsive to the control signal to form the bracket slot according to a predefined electrical discharge cutting pattern derived to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire.

12. A system as defined in claim 11, wherein the bracket is connected to a runner when formed, and wherein the electrical discharge device control instructions include those to perform the operation of executing the electrical discharge cutting pattern extending along a perimeter of the bracket slot to form the bracket slot and to simultaneously separate the bracket from the runner when forming the bracket slot responsive to the control signal.

13. A system as defined in claim 12, wherein the bracket slot includes an open surface end and a closed base end and two spaced-apart sides extending therebetween, and wherein the electrical discharge device control instructions include those to perform the operation of extending an initial portion of the cutting pattern along a portion of an outer surface of the bracket substantially transverse to at least one of the sides.

14. A system as defined in claim 12, wherein the bracket slot includes an open surface end and a closed base end and two spaced-apart sides extending therebetween, wherein the bracket includes a bracket wing having a slot-side surface, and wherein the electrical discharge device control instructions include those to perform the operation of extending a portion of the cutting pattern along the slot-side surface of the bracket wing to thereby form the slot-side surface of the bracket wing.

15. A system as defined in claim 12, wherein the bracket slot includes an open end and a closed base end and two spaced-apart sides extending therebetween, and wherein the electrical discharge device control instructions include those to perform the operation of forming a transverse extension extending into the bracket from one of the spaced-apart sides at the base end of the bracket slot to thereby define a bracket slot undercut.

16. A system as defined in claim 12, wherein the bracket slot includes an open end and a closed base end and two spaced-apart sides extending therebetween spaced apart to define a bracket slot width, and wherein the electrical discharge device control instructions include those to perform the operation of forming a transverse extension extending into the bracket from one of the spaced-apart sides at the base end of the bracket slot to thereby define a bracket slot undercut having an undercut width, the undercut width exceeding the bracket slot width.

17. A system as defined in claim 12, wherein the electrical discharge device control instructions include those to perform the operation of detecting a position on a bracket defining a cutting pattern starting point to begin electrical discharge machining.

18. A system as defined in claim 17, wherein the electrode includes a die-sinker-electrical discharge electrode, and wherein the bracket slot is a tube.

19. A system as defined in claim 12, wherein the electrode includes a wire-cut-electrical discharge electrode, and wherein the bracket slot is specified having at least in one dimension a tolerance of less than 30 microns.

20. A system as defined in claim 12, wherein the archwire-bracket slot interface provides in at least one dimension a play or tolerance of equal to or less than approximately 20 microns.

21. A method of manufacturing orthodontic appliances, the method comprising the steps of: deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute an electrical discharge cutting pattern extending along a perimeter of the bracket slot and configured to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire; andexecuting the electrical discharge cutting pattern responsive to the control signal to form the bracket slot.

22. A method as defined in claim 21, wherein the electrical discharge cutting pattern is customized to substantially match associated dimensions of a preselected archwire.

23. A method as defined in claim 21, wherein prior to executing the electrical discharge cutting pattern, the bracket is connected to a runner, and wherein the step of executing the electrical discharge cutting pattern includes cutting the bracket from the runner to substantially simultaneously separate the bracket from the runner when forming the bracket slot.

24. A method as defined in claim 21, wherein prior to executing the electrical discharge cutting pattern, the bracket is connected to a runner which is connected to a mold tree, and wherein the step of executing the electrical discharge cutting pattern includes the step of cutting the bracket from the mold tree.

25. A method as defined in claim 21, wherein the bracket slot includes an open surface end and a closed base end and two spaced-apart sides extending therebetween, and wherein the step of executing the electrical discharge cutting pattern further includes the step of forming a transverse extension extending into the bracket from one of the spaced-apart sides adjacent the base end of the bracket slot to thereby define a bracket slot undercut.

26. A method as defined in claim 21, wherein the bracket slot includes an open surface end and a closed base end and two sides extending therebetween spaced apart to define a bracket slot width, and wherein the step of executing the electrical discharge cutting pattern further includes the step of forming a transverse extension extending into the bracket from one of the spaced-apart sides adjacent the base end of the bracket slot to thereby define a bracket slot undercut having an undercut width, the undercut width exceeding the bracket slot width.

27. A method as defined in claim 21, wherein the bracket includes a bracket wing, and wherein the step of executing the electrical discharge cutting pattern further includes the step of extending a portion of the cutting pattern along a slot-side surface of the bracket wing to thereby form the slot-side surface of the bracket wing.

28. A method as defined in claim 21, wherein the bracket slot includes an open surface end and a closed base end and two sides extending therebetween, and wherein the step of executing the electrical discharge cutting pattern further includes the step of extending an initial portion of the cutting pattern along a portion of an outer surface of the bracket substantially transverse to at least one of the sides.

29. A method as defined in claim 21, wherein the bracket slot has a bracket slot base and at least two spaced-apart sides, and wherein the step of executing the electrical discharge cutting pattern further includes the step of forming an acute angle between the one of the sides and the bracket slot base so that the two spaced-apart sides converge extending from the bracket slot base.

30. A method as defined in claim 21, wherein the bracket slot is a bracket tube; wherein the electrical discharge cutting pattern is a first electrical discharge cutting pattern, wherein prior to executing the first electrical discharge cutting pattern, the bracket is connected to a runner, and wherein the method further comprises the step of executing a second electrical discharge cutting pattern responsive to the control signal to separate the bracket from the runner.

31. A method as defined in claim 21, wherein the archwire is a customized archwire, and wherein the method further comprises the step of forming the customized archwire adapted to be positioned in the bracket slot to form a bracket slot-archwire interface providing in at least one dimension a play or tolerance of equal to or less than approximately 20 microns.

32. A method of manufacturing orthodontic appliances, the method comprising the steps of: deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute an electrical discharge cutting pattern extending along a perimeter of the bracket slot and configured to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire, the bracket slot having a closed perimeter to thereby define a bracket tube; andexecuting the electrical discharge cutting pattern responsive to a control signal to form the bracket tube.

33. A method as defined in claim 32, wherein the electrical discharge cutting pattern is a first electrical discharge cutting pattern, wherein prior to executing the first electrical discharge cutting pattern the bracket is connected to a runner, and wherein the method further comprises the step of executing a second electrical discharge cutting pattern responsive to the control signal to separate the bracket from the runner.

34. A method as defined in claim 32, wherein the electrical discharge cutting pattern is a first electrical discharge cutting pattern, wherein prior to executing the first electrical discharge cutting pattern, the bracket is connected to a runner which is connected to a mold tree, and wherein the method further comprises the step of executing a second electrical discharge cutting pattern responsive to the control signal to separate the bracket from the mold tree.

35. A method of manufacturing orthodontic appliances, the method comprising the steps of: deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute a machining cutting pattern extending along a perimeter of the bracket slot to form the bracket slot, the bracket slot having an open surface end and a closed base end and two spaced-apart sides extending therebetween; andexecuting the machining cutting pattern responsive to a control signal.

36. A method as defined in claim 35, wherein machining includes milling, drilling, turning, honing, electrical discharge machining, ultrasonic machining, high-pressure water cutting or grinding or a combination thereof.

37. A method as defined in claim 35, wherein the machining cutting pattern extending along a perimeter of the bracket slot and forming a transverse extension extending into the bracket from one of the spaced-apart sides at the base end of the bracket slot to thereby define a bracket slot undercut.

37. A method as defined in claim 35, wherein a distance between the two spaced-apart sides adjacent the base end defines a bracket slot width, and wherein the undercut width exceeds the bracket slot width.

38. A method as defined in claim 35, wherein the orthodontic appliance includes a bracket bonding surface having a shape substantially coinciding with the shape of an associated tooth.

39. A method of manufacturing orthodontic appliances, the method comprising the steps of: deriving a control signal carrying device control instructions describing operations to execute a machining cutting pattern to separate a bracket of an orthodontic appliance from a runner connected thereto; andexecuting the machining cutting pattern responsive to the control signal.

40. A method as defined in claim 39, wherein machining includes milling, drilling, turning, honing, electrical discharge machining, ultrasonic machining, high-pressure water cutting or grinding or a combination thereof.

40. A method as defined in claim 39, wherein the step of deriving a control signal includes receiving a virtual dimensional representation of a bracket slot in the bracket;wherein the operations to execute a machining cutting pattern include those to form the bracket slot;wherein the machining cutting pattern extends along a perimeter of the bracket slot; andwherein the step of executing the machining cutting pattern includes substantially simultaneously separating the bracket from the runner when forming the bracket slot.

41. A method as defined in claim 39, wherein prior to executing the machining cutting pattern, the bracket is connected to a runner which is connected to a mold tree, and wherein the step of executing the electrical discharge cutting pattern includes the step of cutting the bracket from the mold tree.