Methods and systems for post-processing appliance molds

Patent metadata

Field	Value
Publication number	US-11730574-B2
Application number	US-202218046353-A
Country	US
Kind code	B2
Filing date	Oct 13, 2022
Priority date	Apr 13, 2007
Publication date	Aug 22, 2023
Grant date	Aug 22, 2023

Abstract

Methods and systems for post-processing molds are provided. In some embodiments, a method includes using a layer-by-layer build process on a polymeric resin to produce a plurality of aligner molds. The method can include transporting the plurality of aligner molds to a resin removal station. The method can also include applying high pressure air to the plurality of aligner molds to remove residual material from the plurality of aligner molds. The residual material can include excess polymeric resin. The method can further include collecting the excess polymeric resin.

First claim

We claim:

1. A method comprising:
using a layer-by-layer build process on a polymeric resin to produce a plurality of aligner molds;
transporting the plurality of aligner molds to a resin removal station;
applying high pressure air to the plurality of aligner molds to remove residual material from the plurality of aligner molds, wherein the residual material comprises excess polymeric resin, and wherein the plurality of aligner molds are maintained at an elevated temperature configured to enhance removal of the residual material from the plurality of aligner molds; and
collecting the excess polymeric resin.

2. The method of claim 1 , wherein the layer-by-layer build process comprises a stereolithography process.

3. The method of claim 1 , wherein each aligner mold corresponds to a treatment stage for repositioning a patient's teeth.

4. The method of claim 1 , wherein the plurality of aligner molds are built on one or more trays.

5. The method of claim 4 , wherein the plurality of aligner molds are transported to the resin removal station on the one or more trays.

6. The method of claim 4 , wherein the plurality of aligner molds remain on the one or more trays while the high pressure air is applied.

7. The method of claim 4 , further comprising separating the plurality of aligner molds from the one or more trays, after the residual material has been removed.

8. The method of claim 1 , wherein transporting the plurality of aligner molds to the resin removal station and applying the high pressure air to the plurality of aligner molds are performed automatically.

9. The method of claim 1 , wherein the excess polymeric resin is collected for reuse in a subsequent layer-by-layer build process.

10. The method of claim 1 , further comprising transporting the plurality of aligner molds to a curing station.

11. The method of claim 10 , further comprising curing the plurality of aligner molds using reciprocating UV sources.

12. The method of claim 1 , further comprising fabricating a plurality of aligners using the plurality of aligner molds.

13. The method of claim 1 , wherein the elevated temperature is less than a heat deflection temperature of the plurality of aligner molds.

14. A method for manufacturing orthodontic appliance molds, the method comprising:
receiving, at a stereolithography apparatus, a file representing a plurality of treatment stages for repositioning teeth;
building, using the stereolithography apparatus, a plurality of orthodontic appliance molds from a polymeric resin, each orthodontic appliance mold corresponding to a respective treatment stage;
transporting the plurality of orthodontic appliance molds to a resin removal station, wherein the resin removal station is configured to maintain the plurality of orthodontic appliance molds at an elevated temperature configured to enhance removal of residual material from the plurality of orthodontic appliance molds, and wherein the residual material comprises excess polymeric resin;
blowing the residual material off the plurality of orthodontic appliance molds using high pressure air;
collecting the excess polymeric resin separated from the plurality of orthodontic appliance molds for reuse in a subsequent manufacturing process; and
transporting the plurality of orthodontic appliance molds for additional processing.

15. The method of claim 14 , wherein the file comprises a plurality of 3D models, and the plurality of orthodontic appliance molds are built based on the plurality of 3D models.

16. The method of claim 14 , wherein the plurality of orthodontic appliance molds are in a partially cured state, and the additional processing comprises curing the plurality of orthodontic appliance molds.

17. The method of claim 14 , wherein the plurality of orthodontic appliance molds are built on and transported to the resin removal station on a tray.

18. The method of claim 17 , wherein the additional processing comprises removing the plurality of orthodontic appliance molds from the tray.

19. A system for manufacturing aligner molds, the system comprising:
a stereolithography apparatus configured to use a layer-by-layer build process on a polymeric resin to produce a plurality of aligner molds;
a resin removal station comprising a high pressure air source configured to blow residual material off the plurality of aligner molds, wherein the residual material comprises excess polymeric resin, and wherein the resin removal station is configured to maintain the plurality of aligner molds at an elevated temperature to enhance removal of the residual material from the plurality of aligner molds; and
a container configured to collect the excess polymeric resin removed from the plurality of aligner molds.

20. The system of claim 19 , wherein the stereolithography apparatus is configured to:
receive one or more electronic files representing a plurality of treatment stages for repositioning a patient's teeth; and
produce the plurality of aligner molds based on the one or more electronic files.

21. The system of claim 20 , wherein each aligner mold corresponds to a respective treatment stage.

22. The system of claim 20 , wherein the one or more electronic files comprise 3D models of the plurality of aligner molds.

23. The system of claim 19 , further comprising a curing station comprising at least one reciprocating UV source configured to cure the plurality of aligner molds.

24. The system of claim 19 , wherein the stereolithography apparatus is configured to produce the plurality of aligner molds on one or more trays.

25. The system of claim 24 , wherein the high pressure air source is configured to blow the residual material off the plurality of aligner molds while the plurality of aligner molds remain on the one or more trays.

26. The system of claim 24 , further comprising a conveyer line configured to transport the plurality of aligner molds on the one or more trays.

27. The system of claim 26 , wherein the conveyer line comprises a first conveyer belt configured to transport the plurality of aligner molds to the resin removal station, and a second conveyer belt configured to transport the plurality of aligner molds to a curing station.

28. The system of claim 24 , further comprising a removal station configured to separate the plurality of aligner molds from the one or more trays.

29. The system of claim 19 , further comprising a controller configured to control operation of the stereolithography apparatus and the resin removal station.

30. The system of claim 19 , wherein the elevated temperature is less than a heat deflection temperature of the plurality of aligner molds.

Assignees

• Align Technology Inc

Inventors

• Kaza Srinivas
• Sambu Shiva P
• Tata Kamesh
• Doung Michael J
• Phan Long

Classifications

• A61C13/00 Primary

  Dental prostheses; Making same (tooth crowns for capping teeth A61C5/70; dental implants A61C8/00) · CPC title

• F26B5/08 Primary

  by centrifugal treatment · CPC title