Methods for fabricating layered appliances

Patent metadata

Field	Value
Publication number	US-12558193-B2
Application number	US-202318359216-A
Country	US
Kind code	B2
Filing date	Jul 26, 2023
Priority date	Jun 20, 2014
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

Methods for fabricating layered appliances are provided. In some embodiments, a method includes generating a digital model of a polymeric shell including a plurality of tooth-receiving cavities shaped to receive and reposition a patient's teeth from a first arrangement toward a second arrangement. The polymeric shell can include an interior layer having a first stiffness, and an exterior layer having a second stiffness greater than the first stiffness. The exterior layer can include a discontinuity formed therein. The method can further include transmitting the digital model to a fabrication system configured to fabricate the polymeric shell based on the digital model.

First claim

We claim:

1 . A method comprising:
determining a treatment plan for a patient's teeth, the treatment plan comprising repositioning the patient's teeth from a first arrangement toward a second arrangement; generating a digital model of a polymeric shell, wherein the polymeric shell comprises:
a plurality of tooth-receiving cavities shaped to receive the patient's teeth and reposition the patient's teeth from the first arrangement toward the second arrangement,
an interior layer comprising a first stiffness, and
an exterior layer comprising a second stiffness greater than the first stiffness, wherein the exterior layer comprises a discontinuity formed therein, and the discontinuity comprises a cut,
wherein, when the polymeric shell is worn on the patient's teeth, the cut is stretched by placement of the polymeric shell on the patient's teeth, the interior layer interacts with the cut by resisting the stretching, and the interaction between the interior layer and the cut imparts one or more forces to facilitate repositioning of the patient's teeth from the first arrangement toward the second arrangement;
transmitting the digital model to a fabrication system, wherein the fabrication system is configured to fabricate the polymeric shell based on the digital model; and fabricating the polymeric shell based on the digital model.

2 . The method of claim 1 , wherein the fabrication system is configured to fabricate the polymeric shell using a rapid prototyping process.

3 . The method of claim 1 , wherein the cut extends at least partially around a protrusion formed in the exterior layer.

4 . The method of claim 1 , wherein the cut comprises a closed cut.

5 . The method of claim 1 , wherein the cut extends from a buccal surface of the exterior layer to a lingual surface of the exterior layer.

6 . The method of claim 1 , wherein the discontinuity comprises a plurality of cuts in the exterior layer.

7 . The method of claim 1 , wherein the cut defines a flap in the exterior layer and the discontinuity further comprises a plurality of perforations near a joint portion of the flap.

8 . The method of claim 2 , wherein the fabrication system is configured to fabricate the exterior layer from a first material having an elastic modulus within a range from 10,000 psi to 700,000 psi, and to fabricate the interior layer from a second material having an elastic modulus within a range from 100 psi to 50,000 psi.

9 . The method of claim 1 , wherein the discontinuity is shaped to accommodate an attachment mounted on a tooth of the patient, and the one or more forces imparted by the interaction between the interior layer and the cut are applied to the tooth via the attachment.

10 . The method of claim 1 , wherein the discontinuity is formed in the exterior layer to a depth that is less than a thickness of the exterior layer.

11 . The method of claim 1 , wherein the interior layer spans the cut.

12 . The method of claim 1 , wherein the stretching of the cut is configured to decrease as the patient's teeth are repositioned from the first arrangement toward the second arrangement.

13 . The method of claim 1 , wherein the fabricating the polymeric shell comprises using a stereolithography process.

14 . A method comprising:
determining a treatment plan for a patient's teeth, the treatment plan comprising repositioning the patient's teeth from a first arrangement toward a second arrangement; generating a digital model of an aligner configured to receive the patient's teeth and reposition the patient's teeth from the first arrangement toward the second arrangement, the aligner comprising:
a plurality of tooth-receiving cavities,
an interior layer comprising a first stiffness, and
an exterior layer comprising a second stiffness greater than the first stiffness, wherein the exterior layer comprises an opening formed therein,
wherein, when the aligner is worn on the patient's teeth, the opening is stretched by placement of the aligner on the patient's teeth, the interior layer resists the stretching of the opening, and the resistance imparts a force to facilitate repositioning of the patient's teeth from the first arrangement toward the second arrangement;
transmitting the digital model to a fabrication system, wherein the fabrication system is configured to fabricate the aligner based on the digital model; and fabricating the aligner based on the digital model.

15 . The method of claim 14 , wherein the fabrication system is configured to fabricate the aligner using a rapid prototyping process.

16 . The method of claim 14 , wherein the opening extends at least partially around a protrusion formed in the exterior layer.

17 . The method of claim 14 , wherein the exterior layer comprises a plurality of openings formed therein.

18 . The method of claim 14 , wherein the opening defines a flap in the exterior layer and the exterior layer further comprises a plurality of perforations near a joint portion of the flap.

19 . The method of claim 14 , wherein the opening is shaped to accommodate an attachment mounted on a tooth of the patient, and the force imparted by the interaction between the interior layer and the opening is applied to the tooth via the attachment.

20 . The method of claim 14 , wherein the opening is one of a plurality of openings in the exterior layer.

21 . A method comprising:
determining a treatment plan for a patient's teeth, the treatment plan comprising repositioning the patient's teeth from a first arrangement toward a second arrangement; generating a digital model of an aligner configured to receive the patient's teeth and reposition the patient's teeth from the first arrangement toward the second arrangement, the aligner comprising:
a plurality of tooth-receiving cavities,
an interior layer comprising a first stiffness,
an exterior layer comprising a second stiffness greater than the first stiffness, and
a deformable opening formed in the exterior layer and positioned over the interior layer such that the interior layer resists stretching of the deformable opening, wherein the resistance of the interior layer to the stretching of the deformable opening imparts a force to facilitate repositioning of the patient's teeth from the first arrangement toward the second arrangement;
and fabricating, via a fabrication system, the aligner based on the digital model.

22 . The method of claim 21 , wherein the fabrication system is configured to fabricate the aligner using a rapid prototyping process.

23 . The method of claim 21 , wherein the deformable opening extends at least partially around a protrusion formed in the exterior layer.

24 . The method of claim 21 , wherein the exterior layer comprises a plurality of deformable openings formed therein.

25 . The method of claim 21 , wherein the deformable opening defines a flap in the exterior layer and the exterior layer further comprises a plurality of perforations near a joint portion of the flap.

26 . The method of claim 21 , wherein the deformable opening is shaped to accommodate an attachment mounted on a tooth of the patient.

27 . The method of claim 21 , wherein the deformable opening comprises a deformable cut.

28 . The method of claim 21 , wherein the fabrication system is configured to fabricate the exterior layer from a first material having

Assignees

• Align Technology Inc

Inventors

• Kopelman Avi
• Choi Jeeyoung

Classifications

• A61C7/002

  Orthodontic computer assisted systems · CPC title

• Y10T83/0586

  Effecting diverse or sequential cuts in same cutting step · CPC title

• Y10T83/04

  Processes · CPC title

• Y10T29/4957

  Sound device making · CPC title

• A61C7/08 Primary

  Mouthpiece-type retainers {or positioners, e.g. for both the lower and upper arch (arch-shaped medicament applicators for teeth or gums A61C19/063; mouthguards for protecting the teeth of sportsmen A63B71/085)} · CPC title