3D Printing – James D. Hansen, Joseph C. Dingeldein, Shannon D. Scott, Joshua K. Schroeder, Bruce R. Broyles, Mary C. Doruff, 3M Innovative Properties Co
Abstract for “Dental restoration molding techniques.”
A mold body is a custom tool to form a dental restoration in the mouth of a patient. It can be used for at least one tooth. The mold body has a facial section that forms a face surface that corresponds to the tooth’s facial surface. A separate lingual portion forms a lingual area that corresponds with the tooth’s lingual surface. Mold body can be combined with the tooth to create a mold cavity that covers the missing tooth structure.
Background for “Dental restoration molding techniques.”
A dental restoration (or a filling) is a procedure that uses a dental restorative substance to restore function, integrity, and morphology of a missing or irregular tooth structure. A dental restoration can be used to replace missing teeth structure after an external injury, as well as in a restorative procedure for tooth decay or dental caries.
“Restorative dentistry is traditionally the process of removing decay from infected teeth (commonly called?preparing?). The tooth is then removed and the restoration is made using simple tools and skilled craftsmanship. The process of isolation using a rubber dam can be cumbersome. Imperfect technique can lead to contamination, residual flash, or poorly adapted contacts.
“While ?bulk fill? “While?bulk fill? is a fast method of filling deep cavities (e.g. 4-5 mm), many of these restorations are done in one shade because practitioners might not know the right layering protocol for different shades or types. The final filling level and the occlusal geometry of a prepared tooth may be created by overfilling with dental restoration material. This is followed by an iterative process that involves grinding, checking tooth contact, and checking biting function. This is the most time-consuming process for dental restorations. Errors here can result in tooth sensitivity or return visits for adjustment.
This disclosure is about dental restoration techniques that incorporate the direct molding of dental restorative materials directly onto a tooth within the mouth of a patient. The disclosed techniques include custom tools that can be used to restore teeth and methods of producing customized tools for dental repair. Tools that create mold cavities specifically for each patient are among the disclosed techniques. These tools can be made using 3D printing techniques in some cases.
“In one instance, the disclosure is directed at a custom tool to form a dental crown in the mouth of a patient. The mold body allows for a custom fit with at most one patient tooth. The mold body has a facial section that forms a face surface that corresponds to the tooth’s facial surface. It also includes a separate, lingual portion that forms a lingual area that corresponds with the tooth’s lingual surface. Mold body can be combined with the tooth to create a mold cavity that covers the missing tooth structure.
“In another example, this disclosure refers to a kit that includes the custom tool as well as a dental restorative substance.”
“In another example, the disclosure is directed at a method of forming a dental crown in the mouth of a patient. It involves placing a mold over a section of the tooth. The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. The procedure also involves injecting a dental restoration material into the mold cavity. This allows the material to cure in the mold cavity and reforms the tooth. Finally, the patient is removed from the mold.
“In another example, the disclosure is directed at a method of forming a restoration in the mouth of a patient. This involves placing dental restorative material on a portion tooth of the patient and then positioning a mold over that tooth. The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. This involves allowing the dental restoration material to cure in the mold cavity to transform the tooth and then removing the mold from each tooth.
“In another example, the disclosure is directed at a process for making a customized tool for forming dental restorations of teeth within the mouth of a person. This process includes obtaining three-dimensional scan data from a patient’s mouth and three-dimensionally printing the custom tool to form the dental restoration. The custom tool can be combined with the tooth to create a mold cavity that covers the missing tooth structure.
“The accompanying drawings and description below provide details about one or more examples. The claims and the description will reveal other features, objects and benefits of this disclosure.
“BRIEF DESCRIPTION DRAWINGS SHOWING SOME EXAMPLES DURING THIS DISCLOSURE”
“FIG. 1. This is a diagram showing a system to detect and define missing teeth structure using a digital 3-D model. It can be based on intra-oral scans or scans made from models.
“FIGS. “FIGS.
“FIGS. “FIGS.4-6” illustrates a custom tool to form a dental restoration in the mouth of a patient using a mold body that includes a lingual and facial portion that snap together and an occlusal portion.
“FIGS. “FIGS.7-10” illustrates a custom tool to create a dental restoration in the mouth of a patient using a mold body that includes a lingual and a facial section. These parts snap together to form an occlusal mold surface.
“FIGS. 11.-14 show a custom tool to form dental restorations for two adjacent teeth in the mouth of a patient. The mold body includes a lingual and a facial section that snap-fit together, and a sliding occlusal part. This slidable portion includes injection ports for the delivery of dental restorative materials to the mold cavities.
“FIGS. 15-18 show a customized tool to form dental restorations of adjacent teeth in the mouth of a patient. It is designed to allow for separation of adjacent teeth during restoration.
“FIGS. 19-22 show a custom tool to form a dental restoration in the mouth of a patient. It includes a mold body that includes a lingual section and a facial part, clamps that keep them together, and a sliding occlusal portion. A wedge is used to allow for separation of adjacent teeth during restoration.
“FIG. “FIG. 23 is a flowchart that illustrates an example technique to form a dental crown in the mouth of a patient.”
“Conventional dental restoration techniques are often iterative and require significant practitioner skill and experience. This disclosure may include techniques that use custom molds to form dental restorations in the mouth of patients more precisely and faster than is possible with conventional techniques.”
An intraoral scanner can be used to capture a patient’s three-dimensional dentition. A mold may be created based on the 3D (3D) patient’s dentition. These techniques can be used to create high-quality dental restorations that take less time and require less skill than traditional dental restoration techniques.
“FIG. 1. This is a diagram showing a system 10 that can detect and define tooth structure using digital 3D scans. A processor 20 receives digital 3D models (12) of teeth from scans of impressions or intra-oral scans. An electronic display device 16 such as a liquid-crystal display (LCD), can be included in System 10. This device displays indications of changes to tooth shape, and also allows for user input. U.S. Pat. discloses systems for creating digital 3D images and models from image sets from multiple perspectives. Nos. Nos. 7,956,862 & 7,605,817 are both incorporated herein. These systems use an intra-oral scanner for digital images of multiple views of teeth and other intra-oral structures. The digital images are then processed to create a digital 3D model of the scanned teeth. System 10 can be used with a tablet, notebook or desktop computer. The 3D scans can be received locally or remotely by System 10.
“FIGS. 2. and 3. illustrate the components of a customized tool to form a dental crown in the mouth of a patient. FIGS. The mold body of FIGS. 2 and 3 includes a lingual section 30 and facial part 12 that snap-fit together as well as a slidable, occlusal 50. To make the snap-fit connection between facial part 12 and lingual 30, the lingual 30 has recesses 38. These recesses are designed to receive protrusions 24 from facial portion 12. Facial portion 12 and the lingual portion 30 can be held together with a sliding occlusal 50, which includes tabs 56, 56, 57 or alternatively tab 56 and a hinge (as shown in FIGS. 4-6).”
“Facial portion 12 is designed to surround the tooth of a patient. The facial portion 12 creates a customized facial surface 14 for the tooth, while the lingual portion 30 creates a customized lingual surface 32 for the tooth. Facial portion 12 and lingual part 30 create customized distal surfaces 18a and 18b, respectively, which correspond to the surfaces of the teeth, and customized mesial surface 20a and 20b, which correspond to the mesial faces of the tooth. The occlusal portion 50 also forms the occlusal 52, which corresponds to the occlusal surfaces on the tooth. The customized gingival surface 22 a and 22b in the facial portion 12 and the lingual portion 30 seal against the respective gingival surfaces within a patient’s mouth.
The mold cavity is formed by the mold body which includes the facial portion 12, the lingual portion 30, and 50. Mold cavity refers to missing tooth structure, such as tooth structure that was removed to prepare a tooth for removal of a carious lesion or caries to form cavity (FIG.104). 4) suitable for receiving dental restorative material. The mold can be created by placing the custom tool on top of the tooth. This will allow the dental restorative material to be placed into the mold to form the missing tooth structure in cavity 104″
“Facial portion 12 & lingual portion 30 form respective portions of top 26 of the custom-tool as well as inside 28 & inside receiving surface 25, which respectively are designed to accept the slidable Occlusal portion 50 of a mold body. Occlusal part 50 forms bottom surface surface 58. This surface is designed to register with the inside receiving surface 25. Tab 56 is formed by Occlusal part 50. This tab is designed to register with the outer surface 16 on facial portion 12. Tab 57 is designed to register with the outer surface 34 on lingual portion 30. Tabs 56 and 57 may be used to secure the occlusal portion 50 around the tooth.
“Facial section 12 and lingual part 30 can also be configured to register with adjacent teeth in the mouth of a patient to allow for precise placement. Particularly, the facial portion 12 or lingual portion 30 create customized mesial surface 40 a, and 40 b respectively that correspond to mesial tops of the distally neighboring tooth. The distal surfaces 42a and 42b of the facial portion 12 and 30 are customized to correspond with the distal surfaces of mesially adjacent teeth.
“FIGS. 4-6 illustrate custom tool 10. The custom tool 10 is very similar to the one in FIGS. 2. and 3. Except that the occlusal portion 50 has a hinged connection to the lingual portion 30, rather than a sliding connection. The features discussed in relation to FIGS’ custom tool are omitted for simplicity. Custom tool 10 is not the same as custom tool 2. and 3.
“FIGS. The custom tool 10, 106, and 108 are further illustrated in the patient’s mouth. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains crown 102 and cavity 104. Cavity 104 could have been caused by a cavity in tooth 100 that was previously removed using drilling or any other procedure to remove dental material. Facial portion 12 covers the facial surface 116 on tooth 100, while lingual portion 30 covers the lingual surface 120 on tooth 100. Custom tool 10 is used to restore tooth 100, including the surrounding cavity.
“Custom tool 10 can be created based on a digital scan of the patient’s teeth and mouth. This intra-oral 3D scan (e.g. TRUE DEFINITION CANNER) is commercially available from 3M Company in Saint Paul, Minn. There are several ways to capture the digital model dentition. You can scan a dental impression or scan an intraoral scan. Or, you can scan a model that was poured from a dental impression. The scan can be limited to the area of a tooth that needs restoration. A scan may also include the target area, complete tooth restoration, adjacent teeth, soft tissue, and bite registration. Data can be taken during routine checks, when a cavity is diagnosed or during the restorative procedure. Data may be modified by trimming, error correction, and hole filling. To augment the data, additional datasets such as opposing dentition, 2D and 3D xray data of subgingival or internal features, and standard root data that is not specific to a patient may be used.
“In one example, custom tool 10 can be digitally designed with CAD software such as solid modeling software that is based on the digital models. CAD software can be used to create tool blank forms, such as fixed, parametric or library-based tools. Solidworks, NX/Unigraphics, ProEngineer, etc). These objects are usually exported to a separate 3D virtual environment that can manage point cloud and triangular mesh data. It also allows for Boolean operations (e.g. SpaceClaim, Materialise Magics. Optionally, standard forms can be scaled to ensure a good fit between the standard portion and patients’ dentition. You can then subtract the patient data from the standard form. An alternative method to Boolean subtractio is to create a virtual shell that can be attached to the target tooth structure.
“Custom tool 10, was designed to fit over tooth 100 (a first-molar) and portions of adjacent teeth 106,108. The shape 52 of the occlusal surface may correspond to crown 102 before the preparation of cavity104. Another example is that the occlusal surface 52 could correspond to the contact surfaces on the opposing tooth in order to identify the missing tooth structure for crown 102, cavity 104. Another example is that the shape of the occlusal surface 52 can be calculated by flattening or smoothing the digital model of cavity 104. Alternately or additionally, the surface of the occlusal cavity may be created from non-restorative occlusal surfaces (e.g. using the mirror image of the first molar of the arch, or design on the basis of an opposing dentition). The occlusal surface can be designed to provide desired therapeutic benefits, such as opening the bite or optimizing occlusion. Lava Design software is available from 3M Company in Saint Paul, Minn. or 3Shape CAD Design available from 3Shape, Copenhagen, Denmark. Exocad is available from exocad GMBH, Darmstadt, Germany. To design components for custom tool 10, a virtual block can be placed over the digital model. It can then be segmented into mold components. In this case, the facial portion, lingual portion, and 50 may be selected. A digital model may allow for the precise placement of any or all elements of custom tool 10. This is to facilitate the assembly of components in the patient’s mouth and/or access to a mold cavity with a vent or injection port. These custom-located elements can include a partingline, an injection port or a gate. The mold components allow for the assembly of custom tools 10 and 100 on tooth 100, without any geometric interference.
“The design of tool 10, may optionally be tested in a virtual environment that simulates the function of its function in mouth,” said I. To eliminate undercuts in the material, or to create volumes that allow for varying material property changes or gradients, the mold tool or form may be segmented along parting line.
“In the examples of FIGS. The hinged connection attaches the lingual portion 30 to the 4-6 occlusal portions 50. FIGS. FIGS. 2 and 3 show that the occlusal part 50 could be slideably received by facial 12 and lingual 30. The CAD software components can be converted to a 3D point file, or another format, in order to make it easier to use a 3D printer, CNC machine, or any other device. The tool design can then be exported to a machine capable of producing 3D objects such as a CNC mill, or other additive manufacturing/3D printing equipment. To improve the surface finish and release of parts, agents can be used. These parts can then be used in dental procedures. These parts can be printed locally, or sent in a kit that includes adhesives, restorative material, and other consumables. The dental restorative material may be included in the dental capsule, which includes a cannula adapter that fits with the port on the custom-tool.
“In certain examples, components of custom tool 10 were printed on an Object Connex500 with VeroWhite, VeroBlack and Tango+. Also, metered blends of VeroWhite or Tango+ are possible. Optionally, objects could be printed with VeroClear or on a 3D Systems SLA Viper Si2 using Accura 60 and Clearview. VeroBlack is a rigid material while TangoBlack is an elastic material. Both of these materials block actinic radiation. Veroclear and Accura 60 are rigid materials. Tango+ is an elastic material. All of these transmit actinic radiation. You can mix Tango+ with the rigid?Vero family. Materials can be mixed with other materials to reach intermediate durometers. The elastomeric materials’ deformability allows for better compliance and improved release mechanics. Optionally, the material can be chosen to aid in curing a dental restoration material within the mold cavity of the custom-made tool 10.
Production may include optional steps like curing in a UV chamber or cleaning in alcohol solution. Polishing, coating, and/or assembly can be done on various components such as the assembly of the hinged portion of the occlusal portion 50 to 30. To form an occlusal anatomy, the printed custom tool 10 may be used to press into uncured dental restoration material. Custom tool 10 may include optionally engineered fracture lines to facilitate the removal of custom tool 10.
The tool 10, when completed, can be used for dental restorations of tooth 100 and cavity 104. First, the lingual portion 30 may be present in the patient’s mouth. The facial (buccal), portion 12 may also be present. However, tool 100 can optionally be used with additional equipment, such as a matrix band, to separate, separate, or retract the oral tissue. Cavity 104 can be filled with a dental restoration material such as FILTEK Supreme Ultra Universal Restorative. This is available from 3M in Saint Paul, Minn. with a slightly larger amount than cavity 104. The occlusal portion 50 can be closed by rotating about the hinge. Once fully seated, the details of the occlusal surface 52 are transferred to the dental restorative materials 105 (FIG. 6) within cavity 100. This creates a mold cavity that encompasses missing tooth structure (corresponding with cavity 104) by combining occlusal surface 52 from occlusal section 50 and tooth 100.
The hinge can be closed to expose excess restorative dental material. Light curing of the dental restorative material can be done through the tool using an XL3000 curing light. Tool 10, for example, may be made from material that transmits actinic radiation. Molds can also be filled with chemically curing dental materials such as 3M Ketac Molar filling material or 3M Concise composite restorative. After sufficient incubation, the mold can be allowed to cure completely. The tool components can be removed from the patient’s mouth after curing. Flashed (excessive) restorative material may also be removed using a dental scaler. Thus, the restored tooth 100 has an occlusal area that is similar to that of the occlusal section 50’s 52-level occlusal. This allows for intricate surfaces to be created during crown 102 repair of tooth 100.
“In some cases, the facial portion 12, lingual part 30 and occlusal 50 can be designed so that they force separation of teeth 100 to 106 or 108. The geometries for teeth 100, 106 and 108 may be matched by facial portion 12, lingual 30 and 50, with the exception of the interproximal extensions to the gingival surfaces 22a and 22b (FIG. The spaces between teeth 100, 106 and 100 may be slightly larger than those between lingual portion 30, and facial portion 12. The interproximal extensions 22 a- 22 b of the gingival surfaces are shown in FIG. 6.) The interproximal extensions of gingival surfaces 22 a and 22 b may be enlarged in mesial or distal directions so that facial portion 12/lingual portion 30 places outward pressure on either one of the teeth 106,108 or 100. Installing facial portion 12 or lingual portion 30 above teeth 100, 100, and 108 can cause the separation of the spaces between them 100, 106, and 100.
“FIGS. 7-10 show custom tool 210 to form a dental restoration in the mouth of a patient. The mold body of custom tool 210 has a facial portion 212, and a lingual portion 233. Facial portion 212, lingual portion 233, snap-fit together, and are combined to create the desired tooth restoration surface. FIGS. FIGS. 8 and 9 show custom tool 210 combined with teeth 120, 126, 128 in the mouth of a patient. Gingiva 110 is also included in the patient’s mouth. Tooth 120 may contain a large amount of missing material. This material can be ground down to remove decayed material and facilitate the restoration of tooth 120’s entire surface. A 3D image of the patient’s mouth (or a dental impression) can be taken before the decayed material is removed from tooth 120. This may allow for the creation of custom tools 210. The contralateral tooth’s shape can be mirrored in software or a design created using a commercially-available crown design software such as 3Shape CAD Design from 3Shape, Denmark or exocad GMBH from Darmstadt.
“Facial portion 212 forms recesses 238 which are designed to receive protrusions 224, 230 of the lingual portion 233. This creates the snap-fit connection between facial part 212 and lingual section 230.”
“Facial portion 221 and lingual part 230 are designed to surround the tooth of a patient. Particularly, the facial portion 212 creates a customized facial surface (214) of the tooth while the lingual portion (230) forms a customized lingual surface (232). The customized facial surface 214, and the customized lingual surface 232, include custom proximal surface, which correspond to the proximal surface of the tooth, and customized incisal surface, which correspond to the incisal surface of the tooth. The customized gingival surface 222 a, and 222b for the facial portion 212, correspond to the gingival surfaces in the patient’s mouth.
“The mold cavity is formed by the mold body which includes the facial portion 212, lingual portion 233, and tooth 120. The mold cavity includes the missing tooth structure of tooth 120. Restorative dental material can be placed into the mold by placing custom tool 210 on tooth 120. This will allow it to take the shape of the missing tooth structure in tooth 120. Restorative dental material can be placed on tooth 120 before custom tool 210 is assembled over tooth 120. You can place restorative dental material on the surface 214 or 232 of the lingual portion 230 tooth 120 before assembling custom tool 220 over tooth 120. Another example is custom tool 210, which may be assembled first over tooth 120. Then restorative dental material can be injected into mold cavity. One or both of the lingual portions 230 and facial portion 212 may have a port that allows for an injection of restorative material. This is possible after custom tool 210 has been placed over tooth 120.
“Facial portion 221 and lingual part 230 can also be configured to register with adjacent teeth in the mouth of a patient to allow for precise placement. Particularly, the facial portion 212, and the lingual portion, 230, form customized surfaces 240a and 240b that correspond to the surfaces of adjacent teeth 126. The customized surfaces for facial portion 212, and lingual part 230 correspond to the surfaces of adjacent teeth 128. This allows facial portion 212 to register with teeth 128 and 128 respectively, allowing for precise positioning of the custom tool 210 in the mouth of the patient, which will allow for the reconstruction of tooth 120.
“Custom tool 210 allows for simultaneous restorations of multiple teeth. FIG. 8: Like tooth 120, tooth number 126 also contains missing material on the crown of tooth number 126. The custom tool 210 allows for the reconstruction of tooth 126, which is also possible with tooth 120. The custom tool 210 is placed over tooth 120 and tooth 126, creating a second mold cavity that contains the tooth material missing from the crown of tooth 12. To aid in the reconstruction of tooth 12, restorative dental material can be placed in the mold cavity adjacent tooth 126, as described above. Custom tool 210 might include a second port that can receive a injection of restorative material. This is possible when custom tool210 is placed over tooth 120 in order to create the mold cavity next to tooth 126. FIG. FIG. 10. This is a picture of the patient’s mouth after he has had his tooth repaired with a custom tool 210.
“Custom tool 210 can be made in a similar manner to the one previously described in respect to custom tool 10.” It is not necessary to repeat the details of design and manufacturing of custom tool 210, which are described in detail with respect to custom tools 10.
“A crown preparation was made for a patient who needed restoration of their lower right cuspid, tooth 120. A full arch digital impression captured the prepared crown and adjacent dentition. The digital impression was then imported into CAD software. The image of the lower left cuspid was mirrored in order to create the target shape for tooth 120’s lower right cuspid restoration. To create the arch design, the target restoration shape was placed on the crown preparation. The mold was created in software to cover the lower archform. This included the tooth 120 and adjacent teeth 126, 128. A filling port, which can be used to restore a tooth, was digitally removed from the cuspid portion of the mold form. The filling port was located at facial portion 212. It was sized to receive the tip of a commercially-available restorative material compule. This will allow injection of the restorative material into the mold cavity for tooth 12. To facilitate the assembly of the tool components in the restoration process, alignment features 224 and 238 were added to the two parts 212 and 230.
The components of the CAD software (facial portion 212 and lingual part 230) can be converted to a 3D point file or another format to allow for production using a 3D printer, CNC machine, or any other device. Optionally, production may include additional steps like curing (e.g. in a UV chamber) or cleaning (e.g. in an alcohol solution).
“FIGS. “FIGS. The mold body includes the lingual and facial portions 312 and 330, which snap-fit together, and a 350-pound slidable and occlusal portion. The 350-mm slidable occlusal part includes 354a and 354b injection ports for the delivery of dental restorative material into mold cavities of custom tool 3310. These ports correspond to teeth 100 and 101.
“FIGS. “FIGS. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains cavity 104 in crown of tooth 100. Tooth 101 includes cavity 101 in crown of tooth 101. Cavities 104 and 107 could have been cavities that were previously removed by drilling or any other preparation. This is to make it easier to use tool 310 for dental restoration. As the decayed material is not as straight-forward as it used to be, it may be helpful to take a 3D picture of the patient’s mouth before removing it.
“Lingual part 312 and facial section 330 can be used to surround teeth 100, 101. Particularly, the lingual portion 312 creates customized lingual surfaces 314, 315 and facial portion 330 creates customized facial surfaces 332, 332, and 333. Additionally, customized lingual surface 314, 315, and customized facial surfaces 332,333 have customized proximal areas, which correspond to the proximal faces of teeth 100, 101. The customized gingival surface 322a and 322b for the lingual portion and facial portions 312 and 330 correspond to the gingival surfaces in the mouth of the patients.
“Optionally, the lingual portion 312 or facial portion 330 can be configured to include customized gingival surfaces (322 a, 322 b) and an isolation matrix (for a dental restoration). The features of the lingual portion 312 or facial portion 330 could extend subgingivally into hidden interproximal spaces. These extensions can be determined using anatomical averages or patient xray data. Elastomeric material may be used to make the tool fit under patient’s actual dentition. Hydrophilicity can also be a factor in the ability to draw water, saliva and other fluids away form the tooth structure being repaired. You can also incorporate microfluidic channels and vacuum line attachments, as well as bite blocks.
“Occlusal part 350 provides custom occlusal surface 352, which corresponds to the occlusal surface of teeth 100 and 101. Lingual portion 312 is configured to accept the mold body’s slidable 350 occlusal part. Facial portion 330 is also available.
To facilitate the precise placement of the patient’s teeth, the lingual portion 312, facial part 330 and the occlusal section 350 can also register with adjacent teeth (106, 108) within the patient’s mouth. Particularly, the lingual portion 312, 330, and 350 form mesial, proximal, customized surfaces 340a,340b,340c respectively. These correspond to the mesial surfaces on the distally adjacent teeth 108. Lingual portion 312, occlusal part 350, and facial portion 330 form custom distal proximal faces 342a, 342b (distal surface of occlusal 350 not shown), respectively. These surfaces correspond to the distal surfaces of the adjacent tooth 106.
“The mold body, which consists of lingual portion 312, facial part 330, and occlusal section 350, is combined with teeth 100, 101 to create two distinct mold cavities. Mold cavities include missing tooth structure 100-101. The mold cavities can be created by placing a custom tool 310 on top of teeth 100, 101. Restorative dental material can then be placed into the cavities to create the missing tooth structure of cavities, 104, and 107.
“In particular, the occlusal portion 350 contains ports 354a, 354b that are designed to allow injection of restorative dental material into mold cavities. These ports correspond to teeth 101 and 100. After the injection of restorative material into mold cavities using custom tool 310 press 370 to position plugs 374a, 374b and 354b respectively. The bottom surfaces 372a, 374b also include plugs 374a, 374b, which provide defined shapes that correspond to the occlusal surfaces for repaired teeth 101, 100. To prevent misalignment between press 370 and the 350 occlusal portion, plugs 374a, 374b have different shapes (square, circular). Vent holes 355a,355b in the occlusal portion 350 allow air and excess dental material escape from the mold cavities. Material is injected via fill port 354a,354b and press 370 is set up so that plugs 374a,374b fill ports 354a,354b. FIG. FIG. 14 shows the smile of a patient after he has had his teeth repaired with a custom tool 310.
“Custom tool 310 can be made in a similar manner to the custom tool 10 or 210. It is not necessary to repeat the details of the design and manufacturing of custom tool 310, which are described in detail with respect to custom tools 10 and 210.
“Custom tool 310 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done intra-orally using a multichannel scanner. One example is custom tool 310, which can be digitally created using CAD software. Solid modeling software may also be used to create the tool. The custom tool 310 was created to fit over the adjacent teeth 100, 101, and a portion of neighboring teeth 106 and 108. The tooth structure of 100, 101, and 106 can be subtracted digitally from a mold block. Also, fillings and venting ports (354a, 354b, 355a, 355b) may be subtracted. Alternately, the mold block may be created by inverting the tooth structure within software. These ports can be placed in areas of the occlusal area that correspond to the regions of the teeth to be prepared, such as the regions adjacent to the cavities of teeth 100 and 101. To allow the injection of restorative material during filling, filling ports 354a, 354b can be sized to accept a tip of a commercially-available restorative material compule. Vent ports 355a, 355b could be smaller than the filling ports.
To facilitate the assembly of the component parts on the teeth, the mold block design can be divided into three sections (lingual section 312, facial part 330, and occlusal area 350). You can also provide additional segments so that the mold for teeth 100 and 101 can be divided into separate sections. Each of the lingual portion 312, facial part 330, and occlusal section 350 may be broken down into multiple components. To aid in alignment of the occlusal sections on the facial (buccal?)?lingual assembly, the mold block was designed with the occlusal portion bounded on both the mesial- and distal edges. To facilitate the holding of the sections with a hemostat, or cotton pliers, handle features (318), may be added to the lingual portion 312 or facial portion 330.
To ensure alignment with the labial and lingual sections, the occlusal section can include sliders or tabs on the lingual or facial (buccal), sides. A handle section was added to the occlusal section to plug the filling ports 354a, 354b. The plug tips surfaces 372a, 372b may be slightly occlusal to the restoration of teeth 100, 101.
“Components in the CAD software can be converted to a 3D point file or another format to facilitate production using a 3D printer or CNC mill. To facilitate assembly, orientation marks (e.g. a colored mark at the distal ends each tool component) can be applied to the components. Optionally, production may include additional steps like curing (e.g. in a UV oven), cleaning (e.g. in alcohol solution) and/or assembly, polishing tooth surfaces, coating such as with clear acrylic to increase visibility of the restoration area while injecting the restorative dentistry material. Optionally, the surfaces of any tool components that will come in direct contact with the restorative material can be coated with a thin layer (e.g., petroleum jelly) of release agent.
Here’s an example of a restoration for teeth 100, 101 using a custom tool 310. After placement, the matrix bands were trimmed to have slightly higher occlusal-gingival heights than the facial (buccal and lingual) portions. The matrix bands were placed where the tooth structure of the first and third molars (teeth 100, 101) had been removed. To aid with isolation, the lingual portion 312 was placed over the teeth 100 and 101. The facial portion 330 was also assembled to help adapt the matrix band’s shape to the contours 100 and 101. The tooth preparations can be prepared at a depth that is greater than the maximum cure depth recommended for restorative dentistry material. A base layer of dental material can optionally layered into these deep areas and photocured with an 3000 curing lamp. Before adding the final amount of restorative material via ports 354a, 354b, 350 can be placed on the occlusal portion 350. After forming the final amount of restorative material to the desired anatomy, the compule tip was used to inject the restorative material through the filling ports 354a, 354b. Visually monitoring the filling process via the tool and at vent ports 355a, 355b, the filling process was visually monitored through the tool. The removable press 370 was then mated to the 350 occlusal part. Photocuring the final amount of restorative material for both 100 and 101 teeth may be done with tool 310. The occlusal portion 350 is in place. The removable press 370 is in place. After curing, tool310 was removed from patient’s mouth and matrix bands were removed to create a shaped restoration with well-formed contacts. Flashed (excessive) dental material can be removed, such as with a dental scaler.
“FIGS. 15-18 show custom tool 410 used to form dental restorations of two adjacent tooth 100, 101. This is a mold that can be used by a patient to separate adjacent teeth 100 101, 106, and 108 during restoration. Custom tool 410 comprises a mold body, with a facial portion 430 and 412 respectively that snap-fit together. There is also a slidable portion 450. Slidable Occlusal Part 450 includes two injection ports (454 a, 454 B) for the delivery of dental restorative material into mold cavities of custom Tool 410. These ports correspond to teeth 100 and 101.
Custom tool 410 is essentially the same as custom tool 310, except that the geometries in the lingual portion 312, facial part 330, and occlusal section 350 were designed to allow for separation of adjacent teeth 100 to 106 to 108 during restoration, rather than conforming to the positions of individual teeth 100 to 101 to 106 to 108. This allows custom tool to 410 to be used in conjunction with custom tool 310 and conventional direct restorative procedures.
“FIGS. 16 and 17 illustrate the custom tool 410 combined with teeth 100, 101 106, 108, and 108 in the mouth of a patient. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains cavity 104 in crown of tooth 100. Tooth 101 has cavity 107 within the crown crown of tooth 101. Cavities 104 and 107 could have been cavities that were previously removed by drilling or any other preparation. This is to make it easier to use tool 410 for dental restoration. As the shape of the decayed materials may affect the design of custom tool410, it may be possible to take a 3D picture of the patient’s mouth before removing them.
“Lingual part 412 and facial section 430 can be configured to surround teeth 100, 101. Particularly, the lingual portion 412 creates customized lingual surfaces 414 and 415 while the facial portion 430 creates customized facial surfaces 432 and 433. Additionally, the customized lingual surfaces 414-415 and customized facial faces 432, 433, include customized proximal surface, which correspond to the proximal surfaces for teeth 100, 101. The customized gingival surface 422a and 422b correspond to the gingival surfaces in the mouth of the patient.
“Optionally, the lingual portion 412 or facial portion 430 can be configured to include customized gingival surfaces (422 a, 422 b) that serve as an isolation matrix for a restoration. The features of the lingual portion 412 or facial portion 430 could extend subgingivally into the interproximal space. These extensions can be determined using anatomical averages or patient xray data. A patient may require an elastomeric component that is undersized to ensure a tight seal against the patient’s actual dentition geometry. Hydrophilicity can also be a factor in the ability to draw saliva and water away from the tooth structure being repaired. You can also incorporate microfluidic channels and vacuum line attachments, as well as bite blocks.
“Occlusal part 450 provides custom occlusal surface 452, which corresponds to the occlusal surface of teeth 100 and 101. Lingual portion 412, facial portion 430 are configured to accept the slidable portion 450 of a mold body.
To facilitate the precise placement of the patient’s teeth, the lingual portion 412 and facial portion 430 as well as the occlusal part 450 can register with adjacent teeth (106, 108) within the patient’s mouth. Particularly, the lingual portion 412 and facial portion 430 form mesial-proximal surfaces customized 440a,440b,440c respectively. These correspond to mesial surfaces on the distally adjacent teeth 108. Lingual portion 412 and facial portion 430, as well as occlusal part 450, form customized distalproximal surfaces 442a, 442b (distal surface of occlusal section 450 not shown), respectively. These surfaces correspond to the distal surfaces of the adjacent tooth 106.
“The mold body, which consists of lingual portion 412 and facial portion 430, and occlusal part 450, is combined with teeth 100 and 101 to create two distinct mold cavities. Mold cavities include missing tooth structure 100-101. The mold cavities can be created by placing a custom tool 410 on top of teeth 100, 101. Restorative dental material can then be placed into the cavities to create the missing tooth structure of cavities, 104, and 107.
“In particular, the occlusal portion of 450 contains ports 454a, 454b that are designed to allow injection of restorative dental material into mold cavities. This corresponds to teeth 101 and 100. After the injection of restorative material into mold cavities of custom tool410, press470 to position plugs 474a, 474b and 454b respectively. Plugs 474a, 474b also include bottom surfaces 472a, 472b, which provide defined shapes that correspond to the occlusal surface of repaired teeth 101, 100. Vent holes 455a,455b are also included in the occlusal portion of 450 to allow air and excess dental materials to escape from mold cavities. Material is injected via fill port 454a,454b and press 470 so that plugs 474a,474b fill ports 454a,454b. FIG. FIG. 18. This illustration shows the restoration of teeth 101 and 100 in the mouth of a patient after the use custom tool 410.”
“Custom tool410 can be made in a similar manner to the custom tool 10 or custom tool 210. It is not necessary to repeat the details of the design and manufacturing of custom tool410, which are described in detail with respect custom tool 10 or custom tool 220.
“Custom tool 410 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done intra-orally using a multichannel scanner. One example is custom tool 410, which can be digitally created using CAD software. Solid modeling software may also be used to create the tool. Custom tool 410 was created to fit over the adjacent teeth 100, 101, and a portion of neighboring teeth 106 and 108. Contrary to custom tool, 310, the custom tool 410 CAD model was digitally divided at the proximal plans to be restored. The resulting segments were then translated 100 microns each to create a gap between the contacts of teeth 100 to 101 to 106 to 108. Subsequently the tooth structure of 100, 101,106, and 108 as well as filling and venting ports (454a,454b,455a,455b) may be digitally subtracted from a mold block. These ports can be found in areas of the occlusal area that correspond to the regions of the teeth that would eventually be removed during the preparation process. To allow the injection of restorative material during filling, filling ports 454a, 454b can be sized to accept a tip of a commercially-available restorative material compule. The vent ports 455a, 455b could be smaller than the filling ports.
To make it easier to assemble the tool components on the teeth, the mold block design can be divided into three sections (lingual section 412; facial portion 430; occlusal part 450). The arch line was angled at the parting line for lingual portion 412, facial portion 430 and interproximal areas of facial portion 430. This ensures that the ‘wedge’ is not displaced from the arch line. This ensures that if the?wedge? portions come in contact, they will overlap at the contact area. This reduces the chance of material flash during filling. The interproximal “wedge” is a secondary measure. Digitally extended portions of the lingual portion 412, and facial portion 432, were used to create interference of 500 microns. Because of the finite resolution of the printing device used to manufacture, it is possible to lose feature fidelity when sizes decrease to zero (as with a knife edge or wedge). The interproximal “wedge” can be extended. This may be compensated for by components. seen during physical production.”
“The mold block was designed with the occlusal portion in mind. It was bound on the mesial, distal and lateral sides to aid in alignment of the occlusal sections on the facial (buccal?)?lingual assembly. To facilitate the holding of the sections with a hemostat, or cotton pliers, the handle features (418), may be added to the lingual portion 412 or facial portion 430.
To ensure alignment with the labial and lingual sections, the occlusal section can include sliders or tabs on the lingual or facial (buccal), sides. A handle section was added to the occlusal section to plug the filling ports 454a, 454b in such a way that the plug tips surfaces 472a, 472b may be at or slightly occlusal of the restoration of teeth 101, 100.
“The components in the CAD software can be converted to a 3D point file or another format to allow for production with a 3D printer or CNC mill. Orientation marks (i.e. To facilitate assembly, the tool components may have orientation marks (i.e. Optionally, production may include curing in a UV chamber and cleaning with alcohol solution. Polishing of tooth surfaces is another option. Coating, such as with clear acrylic, can be added to improve visibility of the restoration area when the restorative material is injected. Optionally, the surfaces of any tool components that will come in direct contact with restorative material can be coated with a thin layer (e.g., petroleum jelly) of release agent.
Here’s an example of a restoration for teeth 100 and 101 using a custom tool 410. To aid in isolation, to slightly separate and create a matrix between teeth 100, 101, the lingual portion 412 was assembled and the facial portion 430 was placed over them. The tooth preparations can be prepared at a depth that is greater than the maximum cure depth recommended for restorative dentistry material. A base layer of dental material can be added to the deep portions of the preparation. This material can then be photocured using an XL3000 curing light. Before adding the final amount of restorative material via ports 454a, 454b, the occlusal portion (450) can be placed. After forming the final amount of restorative material to the desired anatomy, the compule tip was used to inject the restorative material through the filling ports 444, 454 b, while visually monitoring the process via the tool and at vent ports 455a, 455b. The removable press 470 was then mated with the occlusal part 450. Photocuring the final amount of restorative material for both 100 and 101 teeth may be done with tool 410. The occlusal portion is 450 and the removable presses 470 are in place. After curing, the tool 410 was taken out of the patient’s mouth and the matrix bands were removed. This allowed for a shaped restoration with well-formed contacts. Flashed (excessive) dental material can be removed with a dental scaler, if necessary.
“FIGS. 19-22 show a custom tool 510 that forms a dental restoration in the mouth of a patient. It includes a mold body with facial portion 530, clamps 580a, 580b that hold the facial and lingual portions together, and a sliding occlusal portion of 550. A wedge 590 is used to allow for separation of adjacent teeth during restoration. FIGS. FIGS. 20-21 further illustrate the custom tool 510 when used with teeth 100,106, and 108 in the mouth of a patient. Tooth 100 contains cavity 104 in tooth 100’s crown. Cavity 104 could have been a cavity in tooth 100 that was previously cleaned by drilling. Gingiva 110 is also part of the patient’s mouth. Lingual part 512 can be attached to facial portion530 using clips 580a, 580b. Lingual portions 512 and facial section 530 are designed to surround tooth 100 in the mouth of a patient. Particularly, lingual part 512 forms customized facial 514 of the tooth while facial portion 530 forms customized tongue surface 532 of that tooth.
“Customized lingual and customized facial surfaces 514 and 532 are customized proximal surface, which correspond to the proximal surface of tooth 100. The customized gingival surface 522a and 522b for the patient’s lingual portion 512 and facial part 530 correspond to the gingival surfaces 110 in the patient’s mouth. Occlusal section 550 contains a customized occlusal top 552, which corresponds to the occlusal surfaces 100.
The mold cavity is formed by the mold body which includes the lingual, facial, and occlusal portions. The mold cavity includes cavity 104 within the crown of tooth 100. The custom tool 510 can be placed over tooth 100 to create the cavity for the restorative dental material.
To facilitate the precise placement of the patient’s teeth, the facial portion 530 and lingual portion 512 can also be registered with adjacent teeth 106,108. Particularly, the lingual portion 512, and facial portion 532, form mesial, proximal, customized surfaces 540a and 540b that correspond to mesial surfaces on the distally adjacent tooth (108). The distal proximal customized surfaces 542a and 542b of the lingual portion 512, and facial portion 532, correspond to the distal surfaces of adjacent teeth 106. FIG. FIG. 22 shows a restored tooth 100 and a tooth 101 in the mouth of a patient after the repair using custom tool 510.
“Custom tool 510 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done using an intra-oral 3D scanner such as a multichannel scanner. One example is custom tool 510, which can be digitally created using CAD software. Solid modeling software may also be used to create the custom tool. Custom tool 510 was created to fit over tooth 100 (the tooth to be repaired), and portions of adjacent teeth 106,108. A virtual mold block can be used to design components of custom tool510. This digital model may be placed over the digital mold and then segmented into mold components. In this case, the lingual portion is 512, the facial portion is 530, and the occlusal part is 550.
“The components in the CAD software can be converted to a 3D point file or another format to allow production with a 3D printing machine, CNC mill, or any other device. Optionally, production may include additional steps like curing, cleaning and polishing and/or coating with clear coat or release agent, as described above.
The completed tool 510 can be used for the restoration of tooth 100. To create space between the teeth 100, 100, 106, and/or 100, 108 and seal the gingival part of the matrix, a wedge 590 can be used. The custom-designed tool 510, unlike other off-the-shelf systems for matrixing, allows for space creation and sealing to be managed independently. Optionally, the lingual portion 512 or facial portion 530 can be designed with a slot that allows for a foil/plastic matrix to be inserted from occlusal. This will ensure a customized shape and flash-free contact between 100,106, and 108.
The base of the tooth cavity can optionally be covered with liner/adhesive, and then filled in small increments to limit the thickness of dental restoration material layers. After custom 510 has been placed over tooth 100, the last amount of material can be placed directly onto the tooth using the custom tool510. This will allow the dental restoration material to cure. You can make it easier to remove custom tool 510 by coating custom tool510 with a release agent (e.g. You can make custom tool 510 more flexible by coating it with a release agent (e.g., petroleum jelly, alcohol or silicone).
“In another version, different materials (e.g. Shade, mechanical properties are all specified for placement within the cavity. The custom tools can have lines or multiple occlusal cap designs that indicate the levels of various materials. Each layer can then be pressed or formed to the desired shape using the occlusal caps. These features allow any dentist to create dental restorations that have engineered layers for improved function and appearance.
“Another version of this concept shows that the restoration design was modified from the initial scan data so that some surfaces of an optimized design are placed below the uncut tooth surface. These positions are colored in the custom tool to indicate that the user must excavate these areas before filling the tooth.
“FIG. “FIG.23” is a flowchart that illustrates an example of how to form a dental crown in the mouth of a patient. A practitioner first places a mold (e.g. mold 10, 210 or 310, 410, 510 or 510) over a portion a patient’s tooth (602). The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. The mold cavity is then filled with a dental restoration material (604). To reform the tooth, the practitioner allows the dental restoration material to cure in the mold cavity. This may include using actinic radiation (606). The practitioner then removes the mold from patient’s tooth, leaving the dental restoration in the shape of the mold cavity (608).
“Various examples have been described. These examples are not exclusive. Modifications may be made to them as permitted by this disclosure. You can make custom tools from the initial geometry of your teeth or digitally optimize it. Drawing and scaling data from tooth library, testing in virtual articulator. You can print or mill tools. Tool can be made out of any number of 3D printed materials, including strength, flexibility, translucency and color. You can add features to indicate the fill level of different materials, such as shade, fill level, or physical properties. The mold sections and tools can be interlocked with one another or with other standard components (e.g. Matrix bands can be used to interlock tools/mold sections. You can use tools inside and outside the mouth. Tools can be made to be biodegradable (e.g. To release the restorative material, or to enable undercut geometries/reduce parts lines, solvent/heat can be used. Tools can be made collapsible (deflated or frangible) Kits can be made of specific tools, as well as the associated products and quantities (e.g. You can create kits of the specific tools and associated products that are needed by your patient. A series of tools are used in sequential filling to control the geometry of the multiple layers of a tooth’s dental restoration. To facilitate the fabrication of custom tools, dental scans can be taken during a diagnostic appointment. You can either make the tools locally or send digital scan data to a remote location.
“These and other examples fall within the scope of these claims.”
Summary for “Dental restoration molding techniques.”
A dental restoration (or a filling) is a procedure that uses a dental restorative substance to restore function, integrity, and morphology of a missing or irregular tooth structure. A dental restoration can be used to replace missing teeth structure after an external injury, as well as in a restorative procedure for tooth decay or dental caries.
“Restorative dentistry is traditionally the process of removing decay from infected teeth (commonly called?preparing?). The tooth is then removed and the restoration is made using simple tools and skilled craftsmanship. The process of isolation using a rubber dam can be cumbersome. Imperfect technique can lead to contamination, residual flash, or poorly adapted contacts.
“While ?bulk fill? “While?bulk fill? is a fast method of filling deep cavities (e.g. 4-5 mm), many of these restorations are done in one shade because practitioners might not know the right layering protocol for different shades or types. The final filling level and the occlusal geometry of a prepared tooth may be created by overfilling with dental restoration material. This is followed by an iterative process that involves grinding, checking tooth contact, and checking biting function. This is the most time-consuming process for dental restorations. Errors here can result in tooth sensitivity or return visits for adjustment.
This disclosure is about dental restoration techniques that incorporate the direct molding of dental restorative materials directly onto a tooth within the mouth of a patient. The disclosed techniques include custom tools that can be used to restore teeth and methods of producing customized tools for dental repair. Tools that create mold cavities specifically for each patient are among the disclosed techniques. These tools can be made using 3D printing techniques in some cases.
“In one instance, the disclosure is directed at a custom tool to form a dental crown in the mouth of a patient. The mold body allows for a custom fit with at most one patient tooth. The mold body has a facial section that forms a face surface that corresponds to the tooth’s facial surface. It also includes a separate, lingual portion that forms a lingual area that corresponds with the tooth’s lingual surface. Mold body can be combined with the tooth to create a mold cavity that covers the missing tooth structure.
“In another example, this disclosure refers to a kit that includes the custom tool as well as a dental restorative substance.”
“In another example, the disclosure is directed at a method of forming a dental crown in the mouth of a patient. It involves placing a mold over a section of the tooth. The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. The procedure also involves injecting a dental restoration material into the mold cavity. This allows the material to cure in the mold cavity and reforms the tooth. Finally, the patient is removed from the mold.
“In another example, the disclosure is directed at a method of forming a restoration in the mouth of a patient. This involves placing dental restorative material on a portion tooth of the patient and then positioning a mold over that tooth. The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. This involves allowing the dental restoration material to cure in the mold cavity to transform the tooth and then removing the mold from each tooth.
“In another example, the disclosure is directed at a process for making a customized tool for forming dental restorations of teeth within the mouth of a person. This process includes obtaining three-dimensional scan data from a patient’s mouth and three-dimensionally printing the custom tool to form the dental restoration. The custom tool can be combined with the tooth to create a mold cavity that covers the missing tooth structure.
“The accompanying drawings and description below provide details about one or more examples. The claims and the description will reveal other features, objects and benefits of this disclosure.
“BRIEF DESCRIPTION DRAWINGS SHOWING SOME EXAMPLES DURING THIS DISCLOSURE”
“FIG. 1. This is a diagram showing a system to detect and define missing teeth structure using a digital 3-D model. It can be based on intra-oral scans or scans made from models.
“FIGS. “FIGS.
“FIGS. “FIGS.4-6” illustrates a custom tool to form a dental restoration in the mouth of a patient using a mold body that includes a lingual and facial portion that snap together and an occlusal portion.
“FIGS. “FIGS.7-10” illustrates a custom tool to create a dental restoration in the mouth of a patient using a mold body that includes a lingual and a facial section. These parts snap together to form an occlusal mold surface.
“FIGS. 11.-14 show a custom tool to form dental restorations for two adjacent teeth in the mouth of a patient. The mold body includes a lingual and a facial section that snap-fit together, and a sliding occlusal part. This slidable portion includes injection ports for the delivery of dental restorative materials to the mold cavities.
“FIGS. 15-18 show a customized tool to form dental restorations of adjacent teeth in the mouth of a patient. It is designed to allow for separation of adjacent teeth during restoration.
“FIGS. 19-22 show a custom tool to form a dental restoration in the mouth of a patient. It includes a mold body that includes a lingual section and a facial part, clamps that keep them together, and a sliding occlusal portion. A wedge is used to allow for separation of adjacent teeth during restoration.
“FIG. “FIG. 23 is a flowchart that illustrates an example technique to form a dental crown in the mouth of a patient.”
“Conventional dental restoration techniques are often iterative and require significant practitioner skill and experience. This disclosure may include techniques that use custom molds to form dental restorations in the mouth of patients more precisely and faster than is possible with conventional techniques.”
An intraoral scanner can be used to capture a patient’s three-dimensional dentition. A mold may be created based on the 3D (3D) patient’s dentition. These techniques can be used to create high-quality dental restorations that take less time and require less skill than traditional dental restoration techniques.
“FIG. 1. This is a diagram showing a system 10 that can detect and define tooth structure using digital 3D scans. A processor 20 receives digital 3D models (12) of teeth from scans of impressions or intra-oral scans. An electronic display device 16 such as a liquid-crystal display (LCD), can be included in System 10. This device displays indications of changes to tooth shape, and also allows for user input. U.S. Pat. discloses systems for creating digital 3D images and models from image sets from multiple perspectives. Nos. Nos. 7,956,862 & 7,605,817 are both incorporated herein. These systems use an intra-oral scanner for digital images of multiple views of teeth and other intra-oral structures. The digital images are then processed to create a digital 3D model of the scanned teeth. System 10 can be used with a tablet, notebook or desktop computer. The 3D scans can be received locally or remotely by System 10.
“FIGS. 2. and 3. illustrate the components of a customized tool to form a dental crown in the mouth of a patient. FIGS. The mold body of FIGS. 2 and 3 includes a lingual section 30 and facial part 12 that snap-fit together as well as a slidable, occlusal 50. To make the snap-fit connection between facial part 12 and lingual 30, the lingual 30 has recesses 38. These recesses are designed to receive protrusions 24 from facial portion 12. Facial portion 12 and the lingual portion 30 can be held together with a sliding occlusal 50, which includes tabs 56, 56, 57 or alternatively tab 56 and a hinge (as shown in FIGS. 4-6).”
“Facial portion 12 is designed to surround the tooth of a patient. The facial portion 12 creates a customized facial surface 14 for the tooth, while the lingual portion 30 creates a customized lingual surface 32 for the tooth. Facial portion 12 and lingual part 30 create customized distal surfaces 18a and 18b, respectively, which correspond to the surfaces of the teeth, and customized mesial surface 20a and 20b, which correspond to the mesial faces of the tooth. The occlusal portion 50 also forms the occlusal 52, which corresponds to the occlusal surfaces on the tooth. The customized gingival surface 22 a and 22b in the facial portion 12 and the lingual portion 30 seal against the respective gingival surfaces within a patient’s mouth.
The mold cavity is formed by the mold body which includes the facial portion 12, the lingual portion 30, and 50. Mold cavity refers to missing tooth structure, such as tooth structure that was removed to prepare a tooth for removal of a carious lesion or caries to form cavity (FIG.104). 4) suitable for receiving dental restorative material. The mold can be created by placing the custom tool on top of the tooth. This will allow the dental restorative material to be placed into the mold to form the missing tooth structure in cavity 104″
“Facial portion 12 & lingual portion 30 form respective portions of top 26 of the custom-tool as well as inside 28 & inside receiving surface 25, which respectively are designed to accept the slidable Occlusal portion 50 of a mold body. Occlusal part 50 forms bottom surface surface 58. This surface is designed to register with the inside receiving surface 25. Tab 56 is formed by Occlusal part 50. This tab is designed to register with the outer surface 16 on facial portion 12. Tab 57 is designed to register with the outer surface 34 on lingual portion 30. Tabs 56 and 57 may be used to secure the occlusal portion 50 around the tooth.
“Facial section 12 and lingual part 30 can also be configured to register with adjacent teeth in the mouth of a patient to allow for precise placement. Particularly, the facial portion 12 or lingual portion 30 create customized mesial surface 40 a, and 40 b respectively that correspond to mesial tops of the distally neighboring tooth. The distal surfaces 42a and 42b of the facial portion 12 and 30 are customized to correspond with the distal surfaces of mesially adjacent teeth.
“FIGS. 4-6 illustrate custom tool 10. The custom tool 10 is very similar to the one in FIGS. 2. and 3. Except that the occlusal portion 50 has a hinged connection to the lingual portion 30, rather than a sliding connection. The features discussed in relation to FIGS’ custom tool are omitted for simplicity. Custom tool 10 is not the same as custom tool 2. and 3.
“FIGS. The custom tool 10, 106, and 108 are further illustrated in the patient’s mouth. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains crown 102 and cavity 104. Cavity 104 could have been caused by a cavity in tooth 100 that was previously removed using drilling or any other procedure to remove dental material. Facial portion 12 covers the facial surface 116 on tooth 100, while lingual portion 30 covers the lingual surface 120 on tooth 100. Custom tool 10 is used to restore tooth 100, including the surrounding cavity.
“Custom tool 10 can be created based on a digital scan of the patient’s teeth and mouth. This intra-oral 3D scan (e.g. TRUE DEFINITION CANNER) is commercially available from 3M Company in Saint Paul, Minn. There are several ways to capture the digital model dentition. You can scan a dental impression or scan an intraoral scan. Or, you can scan a model that was poured from a dental impression. The scan can be limited to the area of a tooth that needs restoration. A scan may also include the target area, complete tooth restoration, adjacent teeth, soft tissue, and bite registration. Data can be taken during routine checks, when a cavity is diagnosed or during the restorative procedure. Data may be modified by trimming, error correction, and hole filling. To augment the data, additional datasets such as opposing dentition, 2D and 3D xray data of subgingival or internal features, and standard root data that is not specific to a patient may be used.
“In one example, custom tool 10 can be digitally designed with CAD software such as solid modeling software that is based on the digital models. CAD software can be used to create tool blank forms, such as fixed, parametric or library-based tools. Solidworks, NX/Unigraphics, ProEngineer, etc). These objects are usually exported to a separate 3D virtual environment that can manage point cloud and triangular mesh data. It also allows for Boolean operations (e.g. SpaceClaim, Materialise Magics. Optionally, standard forms can be scaled to ensure a good fit between the standard portion and patients’ dentition. You can then subtract the patient data from the standard form. An alternative method to Boolean subtractio is to create a virtual shell that can be attached to the target tooth structure.
“Custom tool 10, was designed to fit over tooth 100 (a first-molar) and portions of adjacent teeth 106,108. The shape 52 of the occlusal surface may correspond to crown 102 before the preparation of cavity104. Another example is that the occlusal surface 52 could correspond to the contact surfaces on the opposing tooth in order to identify the missing tooth structure for crown 102, cavity 104. Another example is that the shape of the occlusal surface 52 can be calculated by flattening or smoothing the digital model of cavity 104. Alternately or additionally, the surface of the occlusal cavity may be created from non-restorative occlusal surfaces (e.g. using the mirror image of the first molar of the arch, or design on the basis of an opposing dentition). The occlusal surface can be designed to provide desired therapeutic benefits, such as opening the bite or optimizing occlusion. Lava Design software is available from 3M Company in Saint Paul, Minn. or 3Shape CAD Design available from 3Shape, Copenhagen, Denmark. Exocad is available from exocad GMBH, Darmstadt, Germany. To design components for custom tool 10, a virtual block can be placed over the digital model. It can then be segmented into mold components. In this case, the facial portion, lingual portion, and 50 may be selected. A digital model may allow for the precise placement of any or all elements of custom tool 10. This is to facilitate the assembly of components in the patient’s mouth and/or access to a mold cavity with a vent or injection port. These custom-located elements can include a partingline, an injection port or a gate. The mold components allow for the assembly of custom tools 10 and 100 on tooth 100, without any geometric interference.
“The design of tool 10, may optionally be tested in a virtual environment that simulates the function of its function in mouth,” said I. To eliminate undercuts in the material, or to create volumes that allow for varying material property changes or gradients, the mold tool or form may be segmented along parting line.
“In the examples of FIGS. The hinged connection attaches the lingual portion 30 to the 4-6 occlusal portions 50. FIGS. FIGS. 2 and 3 show that the occlusal part 50 could be slideably received by facial 12 and lingual 30. The CAD software components can be converted to a 3D point file, or another format, in order to make it easier to use a 3D printer, CNC machine, or any other device. The tool design can then be exported to a machine capable of producing 3D objects such as a CNC mill, or other additive manufacturing/3D printing equipment. To improve the surface finish and release of parts, agents can be used. These parts can then be used in dental procedures. These parts can be printed locally, or sent in a kit that includes adhesives, restorative material, and other consumables. The dental restorative material may be included in the dental capsule, which includes a cannula adapter that fits with the port on the custom-tool.
“In certain examples, components of custom tool 10 were printed on an Object Connex500 with VeroWhite, VeroBlack and Tango+. Also, metered blends of VeroWhite or Tango+ are possible. Optionally, objects could be printed with VeroClear or on a 3D Systems SLA Viper Si2 using Accura 60 and Clearview. VeroBlack is a rigid material while TangoBlack is an elastic material. Both of these materials block actinic radiation. Veroclear and Accura 60 are rigid materials. Tango+ is an elastic material. All of these transmit actinic radiation. You can mix Tango+ with the rigid?Vero family. Materials can be mixed with other materials to reach intermediate durometers. The elastomeric materials’ deformability allows for better compliance and improved release mechanics. Optionally, the material can be chosen to aid in curing a dental restoration material within the mold cavity of the custom-made tool 10.
Production may include optional steps like curing in a UV chamber or cleaning in alcohol solution. Polishing, coating, and/or assembly can be done on various components such as the assembly of the hinged portion of the occlusal portion 50 to 30. To form an occlusal anatomy, the printed custom tool 10 may be used to press into uncured dental restoration material. Custom tool 10 may include optionally engineered fracture lines to facilitate the removal of custom tool 10.
The tool 10, when completed, can be used for dental restorations of tooth 100 and cavity 104. First, the lingual portion 30 may be present in the patient’s mouth. The facial (buccal), portion 12 may also be present. However, tool 100 can optionally be used with additional equipment, such as a matrix band, to separate, separate, or retract the oral tissue. Cavity 104 can be filled with a dental restoration material such as FILTEK Supreme Ultra Universal Restorative. This is available from 3M in Saint Paul, Minn. with a slightly larger amount than cavity 104. The occlusal portion 50 can be closed by rotating about the hinge. Once fully seated, the details of the occlusal surface 52 are transferred to the dental restorative materials 105 (FIG. 6) within cavity 100. This creates a mold cavity that encompasses missing tooth structure (corresponding with cavity 104) by combining occlusal surface 52 from occlusal section 50 and tooth 100.
The hinge can be closed to expose excess restorative dental material. Light curing of the dental restorative material can be done through the tool using an XL3000 curing light. Tool 10, for example, may be made from material that transmits actinic radiation. Molds can also be filled with chemically curing dental materials such as 3M Ketac Molar filling material or 3M Concise composite restorative. After sufficient incubation, the mold can be allowed to cure completely. The tool components can be removed from the patient’s mouth after curing. Flashed (excessive) restorative material may also be removed using a dental scaler. Thus, the restored tooth 100 has an occlusal area that is similar to that of the occlusal section 50’s 52-level occlusal. This allows for intricate surfaces to be created during crown 102 repair of tooth 100.
“In some cases, the facial portion 12, lingual part 30 and occlusal 50 can be designed so that they force separation of teeth 100 to 106 or 108. The geometries for teeth 100, 106 and 108 may be matched by facial portion 12, lingual 30 and 50, with the exception of the interproximal extensions to the gingival surfaces 22a and 22b (FIG. The spaces between teeth 100, 106 and 100 may be slightly larger than those between lingual portion 30, and facial portion 12. The interproximal extensions 22 a- 22 b of the gingival surfaces are shown in FIG. 6.) The interproximal extensions of gingival surfaces 22 a and 22 b may be enlarged in mesial or distal directions so that facial portion 12/lingual portion 30 places outward pressure on either one of the teeth 106,108 or 100. Installing facial portion 12 or lingual portion 30 above teeth 100, 100, and 108 can cause the separation of the spaces between them 100, 106, and 100.
“FIGS. 7-10 show custom tool 210 to form a dental restoration in the mouth of a patient. The mold body of custom tool 210 has a facial portion 212, and a lingual portion 233. Facial portion 212, lingual portion 233, snap-fit together, and are combined to create the desired tooth restoration surface. FIGS. FIGS. 8 and 9 show custom tool 210 combined with teeth 120, 126, 128 in the mouth of a patient. Gingiva 110 is also included in the patient’s mouth. Tooth 120 may contain a large amount of missing material. This material can be ground down to remove decayed material and facilitate the restoration of tooth 120’s entire surface. A 3D image of the patient’s mouth (or a dental impression) can be taken before the decayed material is removed from tooth 120. This may allow for the creation of custom tools 210. The contralateral tooth’s shape can be mirrored in software or a design created using a commercially-available crown design software such as 3Shape CAD Design from 3Shape, Denmark or exocad GMBH from Darmstadt.
“Facial portion 212 forms recesses 238 which are designed to receive protrusions 224, 230 of the lingual portion 233. This creates the snap-fit connection between facial part 212 and lingual section 230.”
“Facial portion 221 and lingual part 230 are designed to surround the tooth of a patient. Particularly, the facial portion 212 creates a customized facial surface (214) of the tooth while the lingual portion (230) forms a customized lingual surface (232). The customized facial surface 214, and the customized lingual surface 232, include custom proximal surface, which correspond to the proximal surface of the tooth, and customized incisal surface, which correspond to the incisal surface of the tooth. The customized gingival surface 222 a, and 222b for the facial portion 212, correspond to the gingival surfaces in the patient’s mouth.
“The mold cavity is formed by the mold body which includes the facial portion 212, lingual portion 233, and tooth 120. The mold cavity includes the missing tooth structure of tooth 120. Restorative dental material can be placed into the mold by placing custom tool 210 on tooth 120. This will allow it to take the shape of the missing tooth structure in tooth 120. Restorative dental material can be placed on tooth 120 before custom tool 210 is assembled over tooth 120. You can place restorative dental material on the surface 214 or 232 of the lingual portion 230 tooth 120 before assembling custom tool 220 over tooth 120. Another example is custom tool 210, which may be assembled first over tooth 120. Then restorative dental material can be injected into mold cavity. One or both of the lingual portions 230 and facial portion 212 may have a port that allows for an injection of restorative material. This is possible after custom tool 210 has been placed over tooth 120.
“Facial portion 221 and lingual part 230 can also be configured to register with adjacent teeth in the mouth of a patient to allow for precise placement. Particularly, the facial portion 212, and the lingual portion, 230, form customized surfaces 240a and 240b that correspond to the surfaces of adjacent teeth 126. The customized surfaces for facial portion 212, and lingual part 230 correspond to the surfaces of adjacent teeth 128. This allows facial portion 212 to register with teeth 128 and 128 respectively, allowing for precise positioning of the custom tool 210 in the mouth of the patient, which will allow for the reconstruction of tooth 120.
“Custom tool 210 allows for simultaneous restorations of multiple teeth. FIG. 8: Like tooth 120, tooth number 126 also contains missing material on the crown of tooth number 126. The custom tool 210 allows for the reconstruction of tooth 126, which is also possible with tooth 120. The custom tool 210 is placed over tooth 120 and tooth 126, creating a second mold cavity that contains the tooth material missing from the crown of tooth 12. To aid in the reconstruction of tooth 12, restorative dental material can be placed in the mold cavity adjacent tooth 126, as described above. Custom tool 210 might include a second port that can receive a injection of restorative material. This is possible when custom tool210 is placed over tooth 120 in order to create the mold cavity next to tooth 126. FIG. FIG. 10. This is a picture of the patient’s mouth after he has had his tooth repaired with a custom tool 210.
“Custom tool 210 can be made in a similar manner to the one previously described in respect to custom tool 10.” It is not necessary to repeat the details of design and manufacturing of custom tool 210, which are described in detail with respect to custom tools 10.
“A crown preparation was made for a patient who needed restoration of their lower right cuspid, tooth 120. A full arch digital impression captured the prepared crown and adjacent dentition. The digital impression was then imported into CAD software. The image of the lower left cuspid was mirrored in order to create the target shape for tooth 120’s lower right cuspid restoration. To create the arch design, the target restoration shape was placed on the crown preparation. The mold was created in software to cover the lower archform. This included the tooth 120 and adjacent teeth 126, 128. A filling port, which can be used to restore a tooth, was digitally removed from the cuspid portion of the mold form. The filling port was located at facial portion 212. It was sized to receive the tip of a commercially-available restorative material compule. This will allow injection of the restorative material into the mold cavity for tooth 12. To facilitate the assembly of the tool components in the restoration process, alignment features 224 and 238 were added to the two parts 212 and 230.
The components of the CAD software (facial portion 212 and lingual part 230) can be converted to a 3D point file or another format to allow for production using a 3D printer, CNC machine, or any other device. Optionally, production may include additional steps like curing (e.g. in a UV chamber) or cleaning (e.g. in an alcohol solution).
“FIGS. “FIGS. The mold body includes the lingual and facial portions 312 and 330, which snap-fit together, and a 350-pound slidable and occlusal portion. The 350-mm slidable occlusal part includes 354a and 354b injection ports for the delivery of dental restorative material into mold cavities of custom tool 3310. These ports correspond to teeth 100 and 101.
“FIGS. “FIGS. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains cavity 104 in crown of tooth 100. Tooth 101 includes cavity 101 in crown of tooth 101. Cavities 104 and 107 could have been cavities that were previously removed by drilling or any other preparation. This is to make it easier to use tool 310 for dental restoration. As the decayed material is not as straight-forward as it used to be, it may be helpful to take a 3D picture of the patient’s mouth before removing it.
“Lingual part 312 and facial section 330 can be used to surround teeth 100, 101. Particularly, the lingual portion 312 creates customized lingual surfaces 314, 315 and facial portion 330 creates customized facial surfaces 332, 332, and 333. Additionally, customized lingual surface 314, 315, and customized facial surfaces 332,333 have customized proximal areas, which correspond to the proximal faces of teeth 100, 101. The customized gingival surface 322a and 322b for the lingual portion and facial portions 312 and 330 correspond to the gingival surfaces in the mouth of the patients.
“Optionally, the lingual portion 312 or facial portion 330 can be configured to include customized gingival surfaces (322 a, 322 b) and an isolation matrix (for a dental restoration). The features of the lingual portion 312 or facial portion 330 could extend subgingivally into hidden interproximal spaces. These extensions can be determined using anatomical averages or patient xray data. Elastomeric material may be used to make the tool fit under patient’s actual dentition. Hydrophilicity can also be a factor in the ability to draw water, saliva and other fluids away form the tooth structure being repaired. You can also incorporate microfluidic channels and vacuum line attachments, as well as bite blocks.
“Occlusal part 350 provides custom occlusal surface 352, which corresponds to the occlusal surface of teeth 100 and 101. Lingual portion 312 is configured to accept the mold body’s slidable 350 occlusal part. Facial portion 330 is also available.
To facilitate the precise placement of the patient’s teeth, the lingual portion 312, facial part 330 and the occlusal section 350 can also register with adjacent teeth (106, 108) within the patient’s mouth. Particularly, the lingual portion 312, 330, and 350 form mesial, proximal, customized surfaces 340a,340b,340c respectively. These correspond to the mesial surfaces on the distally adjacent teeth 108. Lingual portion 312, occlusal part 350, and facial portion 330 form custom distal proximal faces 342a, 342b (distal surface of occlusal 350 not shown), respectively. These surfaces correspond to the distal surfaces of the adjacent tooth 106.
“The mold body, which consists of lingual portion 312, facial part 330, and occlusal section 350, is combined with teeth 100, 101 to create two distinct mold cavities. Mold cavities include missing tooth structure 100-101. The mold cavities can be created by placing a custom tool 310 on top of teeth 100, 101. Restorative dental material can then be placed into the cavities to create the missing tooth structure of cavities, 104, and 107.
“In particular, the occlusal portion 350 contains ports 354a, 354b that are designed to allow injection of restorative dental material into mold cavities. These ports correspond to teeth 101 and 100. After the injection of restorative material into mold cavities using custom tool 310 press 370 to position plugs 374a, 374b and 354b respectively. The bottom surfaces 372a, 374b also include plugs 374a, 374b, which provide defined shapes that correspond to the occlusal surfaces for repaired teeth 101, 100. To prevent misalignment between press 370 and the 350 occlusal portion, plugs 374a, 374b have different shapes (square, circular). Vent holes 355a,355b in the occlusal portion 350 allow air and excess dental material escape from the mold cavities. Material is injected via fill port 354a,354b and press 370 is set up so that plugs 374a,374b fill ports 354a,354b. FIG. FIG. 14 shows the smile of a patient after he has had his teeth repaired with a custom tool 310.
“Custom tool 310 can be made in a similar manner to the custom tool 10 or 210. It is not necessary to repeat the details of the design and manufacturing of custom tool 310, which are described in detail with respect to custom tools 10 and 210.
“Custom tool 310 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done intra-orally using a multichannel scanner. One example is custom tool 310, which can be digitally created using CAD software. Solid modeling software may also be used to create the tool. The custom tool 310 was created to fit over the adjacent teeth 100, 101, and a portion of neighboring teeth 106 and 108. The tooth structure of 100, 101, and 106 can be subtracted digitally from a mold block. Also, fillings and venting ports (354a, 354b, 355a, 355b) may be subtracted. Alternately, the mold block may be created by inverting the tooth structure within software. These ports can be placed in areas of the occlusal area that correspond to the regions of the teeth to be prepared, such as the regions adjacent to the cavities of teeth 100 and 101. To allow the injection of restorative material during filling, filling ports 354a, 354b can be sized to accept a tip of a commercially-available restorative material compule. Vent ports 355a, 355b could be smaller than the filling ports.
To facilitate the assembly of the component parts on the teeth, the mold block design can be divided into three sections (lingual section 312, facial part 330, and occlusal area 350). You can also provide additional segments so that the mold for teeth 100 and 101 can be divided into separate sections. Each of the lingual portion 312, facial part 330, and occlusal section 350 may be broken down into multiple components. To aid in alignment of the occlusal sections on the facial (buccal?)?lingual assembly, the mold block was designed with the occlusal portion bounded on both the mesial- and distal edges. To facilitate the holding of the sections with a hemostat, or cotton pliers, handle features (318), may be added to the lingual portion 312 or facial portion 330.
To ensure alignment with the labial and lingual sections, the occlusal section can include sliders or tabs on the lingual or facial (buccal), sides. A handle section was added to the occlusal section to plug the filling ports 354a, 354b. The plug tips surfaces 372a, 372b may be slightly occlusal to the restoration of teeth 100, 101.
“Components in the CAD software can be converted to a 3D point file or another format to facilitate production using a 3D printer or CNC mill. To facilitate assembly, orientation marks (e.g. a colored mark at the distal ends each tool component) can be applied to the components. Optionally, production may include additional steps like curing (e.g. in a UV oven), cleaning (e.g. in alcohol solution) and/or assembly, polishing tooth surfaces, coating such as with clear acrylic to increase visibility of the restoration area while injecting the restorative dentistry material. Optionally, the surfaces of any tool components that will come in direct contact with the restorative material can be coated with a thin layer (e.g., petroleum jelly) of release agent.
Here’s an example of a restoration for teeth 100, 101 using a custom tool 310. After placement, the matrix bands were trimmed to have slightly higher occlusal-gingival heights than the facial (buccal and lingual) portions. The matrix bands were placed where the tooth structure of the first and third molars (teeth 100, 101) had been removed. To aid with isolation, the lingual portion 312 was placed over the teeth 100 and 101. The facial portion 330 was also assembled to help adapt the matrix band’s shape to the contours 100 and 101. The tooth preparations can be prepared at a depth that is greater than the maximum cure depth recommended for restorative dentistry material. A base layer of dental material can optionally layered into these deep areas and photocured with an 3000 curing lamp. Before adding the final amount of restorative material via ports 354a, 354b, 350 can be placed on the occlusal portion 350. After forming the final amount of restorative material to the desired anatomy, the compule tip was used to inject the restorative material through the filling ports 354a, 354b. Visually monitoring the filling process via the tool and at vent ports 355a, 355b, the filling process was visually monitored through the tool. The removable press 370 was then mated to the 350 occlusal part. Photocuring the final amount of restorative material for both 100 and 101 teeth may be done with tool 310. The occlusal portion 350 is in place. The removable press 370 is in place. After curing, tool310 was removed from patient’s mouth and matrix bands were removed to create a shaped restoration with well-formed contacts. Flashed (excessive) dental material can be removed, such as with a dental scaler.
“FIGS. 15-18 show custom tool 410 used to form dental restorations of two adjacent tooth 100, 101. This is a mold that can be used by a patient to separate adjacent teeth 100 101, 106, and 108 during restoration. Custom tool 410 comprises a mold body, with a facial portion 430 and 412 respectively that snap-fit together. There is also a slidable portion 450. Slidable Occlusal Part 450 includes two injection ports (454 a, 454 B) for the delivery of dental restorative material into mold cavities of custom Tool 410. These ports correspond to teeth 100 and 101.
Custom tool 410 is essentially the same as custom tool 310, except that the geometries in the lingual portion 312, facial part 330, and occlusal section 350 were designed to allow for separation of adjacent teeth 100 to 106 to 108 during restoration, rather than conforming to the positions of individual teeth 100 to 101 to 106 to 108. This allows custom tool to 410 to be used in conjunction with custom tool 310 and conventional direct restorative procedures.
“FIGS. 16 and 17 illustrate the custom tool 410 combined with teeth 100, 101 106, 108, and 108 in the mouth of a patient. Gingiva 110 is also included in the mouth of the patient. Tooth 100 contains cavity 104 in crown of tooth 100. Tooth 101 has cavity 107 within the crown crown of tooth 101. Cavities 104 and 107 could have been cavities that were previously removed by drilling or any other preparation. This is to make it easier to use tool 410 for dental restoration. As the shape of the decayed materials may affect the design of custom tool410, it may be possible to take a 3D picture of the patient’s mouth before removing them.
“Lingual part 412 and facial section 430 can be configured to surround teeth 100, 101. Particularly, the lingual portion 412 creates customized lingual surfaces 414 and 415 while the facial portion 430 creates customized facial surfaces 432 and 433. Additionally, the customized lingual surfaces 414-415 and customized facial faces 432, 433, include customized proximal surface, which correspond to the proximal surfaces for teeth 100, 101. The customized gingival surface 422a and 422b correspond to the gingival surfaces in the mouth of the patient.
“Optionally, the lingual portion 412 or facial portion 430 can be configured to include customized gingival surfaces (422 a, 422 b) that serve as an isolation matrix for a restoration. The features of the lingual portion 412 or facial portion 430 could extend subgingivally into the interproximal space. These extensions can be determined using anatomical averages or patient xray data. A patient may require an elastomeric component that is undersized to ensure a tight seal against the patient’s actual dentition geometry. Hydrophilicity can also be a factor in the ability to draw saliva and water away from the tooth structure being repaired. You can also incorporate microfluidic channels and vacuum line attachments, as well as bite blocks.
“Occlusal part 450 provides custom occlusal surface 452, which corresponds to the occlusal surface of teeth 100 and 101. Lingual portion 412, facial portion 430 are configured to accept the slidable portion 450 of a mold body.
To facilitate the precise placement of the patient’s teeth, the lingual portion 412 and facial portion 430 as well as the occlusal part 450 can register with adjacent teeth (106, 108) within the patient’s mouth. Particularly, the lingual portion 412 and facial portion 430 form mesial-proximal surfaces customized 440a,440b,440c respectively. These correspond to mesial surfaces on the distally adjacent teeth 108. Lingual portion 412 and facial portion 430, as well as occlusal part 450, form customized distalproximal surfaces 442a, 442b (distal surface of occlusal section 450 not shown), respectively. These surfaces correspond to the distal surfaces of the adjacent tooth 106.
“The mold body, which consists of lingual portion 412 and facial portion 430, and occlusal part 450, is combined with teeth 100 and 101 to create two distinct mold cavities. Mold cavities include missing tooth structure 100-101. The mold cavities can be created by placing a custom tool 410 on top of teeth 100, 101. Restorative dental material can then be placed into the cavities to create the missing tooth structure of cavities, 104, and 107.
“In particular, the occlusal portion of 450 contains ports 454a, 454b that are designed to allow injection of restorative dental material into mold cavities. This corresponds to teeth 101 and 100. After the injection of restorative material into mold cavities of custom tool410, press470 to position plugs 474a, 474b and 454b respectively. Plugs 474a, 474b also include bottom surfaces 472a, 472b, which provide defined shapes that correspond to the occlusal surface of repaired teeth 101, 100. Vent holes 455a,455b are also included in the occlusal portion of 450 to allow air and excess dental materials to escape from mold cavities. Material is injected via fill port 454a,454b and press 470 so that plugs 474a,474b fill ports 454a,454b. FIG. FIG. 18. This illustration shows the restoration of teeth 101 and 100 in the mouth of a patient after the use custom tool 410.”
“Custom tool410 can be made in a similar manner to the custom tool 10 or custom tool 210. It is not necessary to repeat the details of the design and manufacturing of custom tool410, which are described in detail with respect custom tool 10 or custom tool 220.
“Custom tool 410 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done intra-orally using a multichannel scanner. One example is custom tool 410, which can be digitally created using CAD software. Solid modeling software may also be used to create the tool. Custom tool 410 was created to fit over the adjacent teeth 100, 101, and a portion of neighboring teeth 106 and 108. Contrary to custom tool, 310, the custom tool 410 CAD model was digitally divided at the proximal plans to be restored. The resulting segments were then translated 100 microns each to create a gap between the contacts of teeth 100 to 101 to 106 to 108. Subsequently the tooth structure of 100, 101,106, and 108 as well as filling and venting ports (454a,454b,455a,455b) may be digitally subtracted from a mold block. These ports can be found in areas of the occlusal area that correspond to the regions of the teeth that would eventually be removed during the preparation process. To allow the injection of restorative material during filling, filling ports 454a, 454b can be sized to accept a tip of a commercially-available restorative material compule. The vent ports 455a, 455b could be smaller than the filling ports.
To make it easier to assemble the tool components on the teeth, the mold block design can be divided into three sections (lingual section 412; facial portion 430; occlusal part 450). The arch line was angled at the parting line for lingual portion 412, facial portion 430 and interproximal areas of facial portion 430. This ensures that the ‘wedge’ is not displaced from the arch line. This ensures that if the?wedge? portions come in contact, they will overlap at the contact area. This reduces the chance of material flash during filling. The interproximal “wedge” is a secondary measure. Digitally extended portions of the lingual portion 412, and facial portion 432, were used to create interference of 500 microns. Because of the finite resolution of the printing device used to manufacture, it is possible to lose feature fidelity when sizes decrease to zero (as with a knife edge or wedge). The interproximal “wedge” can be extended. This may be compensated for by components. seen during physical production.”
“The mold block was designed with the occlusal portion in mind. It was bound on the mesial, distal and lateral sides to aid in alignment of the occlusal sections on the facial (buccal?)?lingual assembly. To facilitate the holding of the sections with a hemostat, or cotton pliers, the handle features (418), may be added to the lingual portion 412 or facial portion 430.
To ensure alignment with the labial and lingual sections, the occlusal section can include sliders or tabs on the lingual or facial (buccal), sides. A handle section was added to the occlusal section to plug the filling ports 454a, 454b in such a way that the plug tips surfaces 472a, 472b may be at or slightly occlusal of the restoration of teeth 101, 100.
“The components in the CAD software can be converted to a 3D point file or another format to allow for production with a 3D printer or CNC mill. Orientation marks (i.e. To facilitate assembly, the tool components may have orientation marks (i.e. Optionally, production may include curing in a UV chamber and cleaning with alcohol solution. Polishing of tooth surfaces is another option. Coating, such as with clear acrylic, can be added to improve visibility of the restoration area when the restorative material is injected. Optionally, the surfaces of any tool components that will come in direct contact with restorative material can be coated with a thin layer (e.g., petroleum jelly) of release agent.
Here’s an example of a restoration for teeth 100 and 101 using a custom tool 410. To aid in isolation, to slightly separate and create a matrix between teeth 100, 101, the lingual portion 412 was assembled and the facial portion 430 was placed over them. The tooth preparations can be prepared at a depth that is greater than the maximum cure depth recommended for restorative dentistry material. A base layer of dental material can be added to the deep portions of the preparation. This material can then be photocured using an XL3000 curing light. Before adding the final amount of restorative material via ports 454a, 454b, the occlusal portion (450) can be placed. After forming the final amount of restorative material to the desired anatomy, the compule tip was used to inject the restorative material through the filling ports 444, 454 b, while visually monitoring the process via the tool and at vent ports 455a, 455b. The removable press 470 was then mated with the occlusal part 450. Photocuring the final amount of restorative material for both 100 and 101 teeth may be done with tool 410. The occlusal portion is 450 and the removable presses 470 are in place. After curing, the tool 410 was taken out of the patient’s mouth and the matrix bands were removed. This allowed for a shaped restoration with well-formed contacts. Flashed (excessive) dental material can be removed with a dental scaler, if necessary.
“FIGS. 19-22 show a custom tool 510 that forms a dental restoration in the mouth of a patient. It includes a mold body with facial portion 530, clamps 580a, 580b that hold the facial and lingual portions together, and a sliding occlusal portion of 550. A wedge 590 is used to allow for separation of adjacent teeth during restoration. FIGS. FIGS. 20-21 further illustrate the custom tool 510 when used with teeth 100,106, and 108 in the mouth of a patient. Tooth 100 contains cavity 104 in tooth 100’s crown. Cavity 104 could have been a cavity in tooth 100 that was previously cleaned by drilling. Gingiva 110 is also part of the patient’s mouth. Lingual part 512 can be attached to facial portion530 using clips 580a, 580b. Lingual portions 512 and facial section 530 are designed to surround tooth 100 in the mouth of a patient. Particularly, lingual part 512 forms customized facial 514 of the tooth while facial portion 530 forms customized tongue surface 532 of that tooth.
“Customized lingual and customized facial surfaces 514 and 532 are customized proximal surface, which correspond to the proximal surface of tooth 100. The customized gingival surface 522a and 522b for the patient’s lingual portion 512 and facial part 530 correspond to the gingival surfaces 110 in the patient’s mouth. Occlusal section 550 contains a customized occlusal top 552, which corresponds to the occlusal surfaces 100.
The mold cavity is formed by the mold body which includes the lingual, facial, and occlusal portions. The mold cavity includes cavity 104 within the crown of tooth 100. The custom tool 510 can be placed over tooth 100 to create the cavity for the restorative dental material.
To facilitate the precise placement of the patient’s teeth, the facial portion 530 and lingual portion 512 can also be registered with adjacent teeth 106,108. Particularly, the lingual portion 512, and facial portion 532, form mesial, proximal, customized surfaces 540a and 540b that correspond to mesial surfaces on the distally adjacent tooth (108). The distal proximal customized surfaces 542a and 542b of the lingual portion 512, and facial portion 532, correspond to the distal surfaces of adjacent teeth 106. FIG. FIG. 22 shows a restored tooth 100 and a tooth 101 in the mouth of a patient after the repair using custom tool 510.
“Custom tool 510 can be created based on a digital model that shows the mouth and teeth of a patient. This scan can be done using an intra-oral 3D scanner such as a multichannel scanner. One example is custom tool 510, which can be digitally created using CAD software. Solid modeling software may also be used to create the custom tool. Custom tool 510 was created to fit over tooth 100 (the tooth to be repaired), and portions of adjacent teeth 106,108. A virtual mold block can be used to design components of custom tool510. This digital model may be placed over the digital mold and then segmented into mold components. In this case, the lingual portion is 512, the facial portion is 530, and the occlusal part is 550.
“The components in the CAD software can be converted to a 3D point file or another format to allow production with a 3D printing machine, CNC mill, or any other device. Optionally, production may include additional steps like curing, cleaning and polishing and/or coating with clear coat or release agent, as described above.
The completed tool 510 can be used for the restoration of tooth 100. To create space between the teeth 100, 100, 106, and/or 100, 108 and seal the gingival part of the matrix, a wedge 590 can be used. The custom-designed tool 510, unlike other off-the-shelf systems for matrixing, allows for space creation and sealing to be managed independently. Optionally, the lingual portion 512 or facial portion 530 can be designed with a slot that allows for a foil/plastic matrix to be inserted from occlusal. This will ensure a customized shape and flash-free contact between 100,106, and 108.
The base of the tooth cavity can optionally be covered with liner/adhesive, and then filled in small increments to limit the thickness of dental restoration material layers. After custom 510 has been placed over tooth 100, the last amount of material can be placed directly onto the tooth using the custom tool510. This will allow the dental restoration material to cure. You can make it easier to remove custom tool 510 by coating custom tool510 with a release agent (e.g. You can make custom tool 510 more flexible by coating it with a release agent (e.g., petroleum jelly, alcohol or silicone).
“In another version, different materials (e.g. Shade, mechanical properties are all specified for placement within the cavity. The custom tools can have lines or multiple occlusal cap designs that indicate the levels of various materials. Each layer can then be pressed or formed to the desired shape using the occlusal caps. These features allow any dentist to create dental restorations that have engineered layers for improved function and appearance.
“Another version of this concept shows that the restoration design was modified from the initial scan data so that some surfaces of an optimized design are placed below the uncut tooth surface. These positions are colored in the custom tool to indicate that the user must excavate these areas before filling the tooth.
“FIG. “FIG.23” is a flowchart that illustrates an example of how to form a dental crown in the mouth of a patient. A practitioner first places a mold (e.g. mold 10, 210 or 310, 410, 510 or 510) over a portion a patient’s tooth (602). The mold is combined with the tooth to create a mold cavity that covers the missing tooth structure. The mold cavity is then filled with a dental restoration material (604). To reform the tooth, the practitioner allows the dental restoration material to cure in the mold cavity. This may include using actinic radiation (606). The practitioner then removes the mold from patient’s tooth, leaving the dental restoration in the shape of the mold cavity (608).
“Various examples have been described. These examples are not exclusive. Modifications may be made to them as permitted by this disclosure. You can make custom tools from the initial geometry of your teeth or digitally optimize it. Drawing and scaling data from tooth library, testing in virtual articulator. You can print or mill tools. Tool can be made out of any number of 3D printed materials, including strength, flexibility, translucency and color. You can add features to indicate the fill level of different materials, such as shade, fill level, or physical properties. The mold sections and tools can be interlocked with one another or with other standard components (e.g. Matrix bands can be used to interlock tools/mold sections. You can use tools inside and outside the mouth. Tools can be made to be biodegradable (e.g. To release the restorative material, or to enable undercut geometries/reduce parts lines, solvent/heat can be used. Tools can be made collapsible (deflated or frangible) Kits can be made of specific tools, as well as the associated products and quantities (e.g. You can create kits of the specific tools and associated products that are needed by your patient. A series of tools are used in sequential filling to control the geometry of the multiple layers of a tooth’s dental restoration. To facilitate the fabrication of custom tools, dental scans can be taken during a diagnostic appointment. You can either make the tools locally or send digital scan data to a remote location.
“These and other examples fall within the scope of these claims.”
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Are you interested in similar patents? These are the steps to follow:
1. Brainstorm terms to describe your invention, based on its purpose, composition, or use.
Write down a brief, but precise description of the invention. Don’t use generic terms such as “device”, “process,” or “system”. Consider synonyms for the terms you chose initially. Next, take note of important technical terms as well as keywords.
Use the questions below to help you identify keywords or concepts.
- What is the purpose of the invention Is it a utilitarian device or an ornamental design?
- Is invention a way to create something or perform a function? Is it a product?
- What is the composition and function of the invention? What is the physical composition of the invention?
- What’s the purpose of the invention
- What are the technical terms and keywords used to describe an invention’s nature? A technical dictionary can help you locate the right terms.
2. These terms will allow you to search for relevant Cooperative Patent Classifications at Classification Search Tool. If you are unable to find the right classification for your invention, scan through the classification’s class Schemas (class schedules) and try again. If you don’t get any results from the Classification Text Search, you might consider substituting your words to describe your invention with synonyms.
3. Check the CPC Classification Definition for confirmation of the CPC classification you found. If the selected classification title has a blue box with a “D” at its left, the hyperlink will take you to a CPC classification description. CPC classification definitions will help you determine the applicable classification’s scope so that you can choose the most relevant. These definitions may also include search tips or other suggestions that could be helpful for further research.
4. The Patents Full-Text Database and the Image Database allow you to retrieve patent documents that include the CPC classification. By focusing on the abstracts and representative drawings, you can narrow down your search for the most relevant patent publications.
5. This selection of patent publications is the best to look at for any similarities to your invention. Pay attention to the claims and specification. Refer to the applicant and patent examiner for additional patents.
6. You can retrieve published patent applications that match the CPC classification you chose in Step 3. You can also use the same search strategy that you used in Step 4 to narrow your search results to only the most relevant patent applications by reviewing the abstracts and representative drawings for each page. Next, examine all published patent applications carefully, paying special attention to the claims, and other drawings.
7. You can search for additional US patent publications by keyword searching in AppFT or PatFT databases, as well as classification searching of patents not from the United States per below. Also, you can use web search engines to search non-patent literature disclosures about inventions. Here are some examples:
- Add keywords to your search. Keyword searches may turn up documents that are not well-categorized or have missed classifications during Step 2. For example, US patent examiners often supplement their classification searches with keyword searches. Think about the use of technical engineering terminology rather than everyday words.
- Search for foreign patents using the CPC classification. Then, re-run the search using international patent office search engines such as Espacenet, the European Patent Office’s worldwide patent publication database of over 130 million patent publications. Other national databases include:
- European Patent Office (EPO) provides esp@cenet to access a network of Europe’s patent databases with access to machine translation of European patents.
- Japan Patent Office (JPO) – with access to machine translations of Japanese patents.
- World Intellectual Property Organization (WIPO) offers PATENTSCOPE with a full-text search of published international patent applications and machine translations for some documents, as well as a list of international patent databases.
- Korean Intellectual Property Rights Information Service (KIPRIS)
- State Intellectual Property Office (SIPO) with machine translation of Chinese patents.
- Other International Intellectual Property Offices with online patent databases include Australia, Canada, Denmark, Finland, France, Germany, Great Britain, India, Israel, Netherlands, Norway, Sweden, Switzerland, and Taiwan.
- Search non-patent literature. Inventions can be made public in many non-patent publications. It is recommended that you search journals, books, websites, technical catalogs, conference proceedings, and other print and electronic publications.
To review your search, you can hire a registered patent attorney to assist. A preliminary search will help one better prepare to talk about their invention and other related inventions with a professional patent attorney. In addition, the attorney will not spend too much time or money on patenting basics.
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