# US 11,897,205 B2 · Laser-based support structure removal > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,897,205 B2 - Document ID: US11897205B2 - Status: Granted - Kind: B2 - Application number: 17/831,059 - Filed: 2022-06-02 - Published: 2023-12-07 - Granted: 2024-02-13 - Earliest claimed: 2022-06-02 - Assignees: SDC U.S. SmilePay SPV - Applicants: SDC U.S. SmilePay SPV - Inventors: Tim Wucher; John Dargis; Eric Wagnon; Drew Marschner; Charlotte Xia; Justin Kreil - Web page: https://patentgrep.com/patent/US11897205B2 ## CPC - B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof - A61C 7/002: {Orthodontic computer assisted systems} - A61C 7/08: Mouthpiece-type retainers {or positioners, e.g. for both the lower and upper arch (arch-shaped medicament applicators for teeth or gums A61C19/063; mouthguards for protecting the teeth of sportsmen A63B71/085)} - B23K 26/38: by boring or cutting - B29C 64/182: in parallel batches - B29C 64/386: Data acquisition or data processing for additive manufacturing - B29C 64/393: for controlling or regulating additive manufacturing processes - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B33Y 50/00: Data acquisition or data processing for additive manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 80/00: Products made by additive manufacturing - B29L 2031/753: {Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008)} - B29L 2031/7536: {Artificial teeth} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A61C: DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE (non-driven toothbrushes A46B; {tongue scrapers A61B17/24;} preparations for dentistry A61K6/00; preparations for cleaning the teeth or mouth A61K8/00, A61Q11/00) - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract Systems and methods for fabricating a dental aligner are provided. The system includes a computing system to receive and prepare a digital model of a dental aligner by adding one or more support structures to the digital model. The system includes a fabrication system to manufacture the dental aligner with the one or more support structures. The system includes a laser system to receive the fabricated dental aligner, orient the dental aligner relative to the laser system, and laser cut an interface between the support structures and the dental aligner to remove the one or more support structures from the dental aligner. ## Claims ### Claim 1 A method comprising: receiving, by a computing system, a first digital model of a first dental aligner configured to move one or more teeth based on a generated treatment plan; receiving, by the computing system, a second digital model of a second dental aligner configured to move one or more teeth based on a second generated treatment plan; preparing, by the computing system, the first digital model of the first dental aligner for manufacturing, wherein preparing the first digital model of the first dental aligner includes modifying the first digital model by adding one or more support structures to the first digital model to be formed with the first dental aligner; preparing, by the computing system, the second digital model of the second dental aligner for manufacturing, wherein preparing the second digital model of the second dental aligner includes analyzing a size or shape of the second digital model of the second dental aligner and a size or shape of the first digital model of the first dental aligner; forming, via additive manufacturing, the first dental aligner with the one or more support structures based on the modified first digital model; forming, via additive manufacturing, the second dental aligner simultaneously with the first dental aligner; receiving, by a laser system, the first dental aligner with the one or more support structures; orienting, by the laser system, the first dental aligner with the one or more support structures relative to the laser system, wherein orienting the first dental aligner includes locating one or more features of the first dental aligner relative to the laser system; and cutting, by the laser system, an interface between the support structures and the first dental aligner to remove the one or more support structures from the first dental aligner. ### Claim 2 (depends on 1) The method of claim 1, wherein: the one or more support structures includes a continuous support that extends a length along a portion of a surface of the first dental aligner; the length is greater than 0.35 millimeters; and cutting the interface includes making a continuous cut along the length of the continuous support. ### Claim 3 (depends on 1) The method of claim 1, wherein forming the first dental aligner includes: fabricating, by a fabrication system, the first dental aligner layer-by-layer at an angle relative to a normal of a surface; and wherein the angle is in a range of 5 degrees to 45 degrees relative to the normal of the surface. ### Claim 4 (depends on 3) The method of claim 3, wherein adding the one or more support structures to the first digital model to be formed with the first dental aligner is based on the angle of the first dental aligner relative to the normal. ### Claim 5 (depends on 3) The method of claim 3, wherein modifying the first digital model by adding the one or more support structures to the first digital model to be formed with the first dental aligner includes: determining, by the computing system, an attachment position of the one or more support structures relative to the first dental aligner based on the angle; and wherein the attachment position includes at least one of an occlusal surface or an edge of the first dental aligner. ### Claim 6 (depends on 1) The method of claim 1, wherein: the one or more features of the first dental aligner includes at least one of a fiducial, a data matrix, or a readable indicium; and the one or more features are positioned on at least one support structure of the first dental aligner. ### Claim 7 (depends on 1) The method of claim 1, wherein: the one or more support structures includes a plurality of support structures; a first support structure of the plurality of support structures is positioned along an edge of the first dental aligner and a second support structure of the plurality of support structures is positioned towards a center of the first dental aligner; and cutting the interface includes cutting the first support structure prior to cutting the second support structure. ### Claim 8 A system comprising: a fabrication computing system having one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to: receive a first digital model of a first dental aligner configured to move one or more teeth based on a generated treatment plan; receive a second digital model of a second dental aligner configured to move one or more teeth based on a second generated treatment plan; prepare the first digital model of the first dental aligner for manufacturing, wherein preparing the first digital model of the first dental aligner includes modifying the first digital model by adding one or more support structures to the first digital model to be formed with the first dental aligner; and prepare the second digital model of the second dental aligner for manufacturing, wherein preparing the second digital model of the second dental aligner includes analyzing a size or shape of the second digital model of the second dental aligner and a size or shape of the first digital model of the first dental aligner; a 3D printing fabrication system configured to print the first dental aligner with the one or more support structures and the second dental aligner simultaneously; and a laser system having one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to: orient, by a fixture, the first dental aligner with the one or more support structures, wherein orienting the first dental aligner includes locating one or more features of the first dental aligner relative to the laser system; and cut, by a laser beam, an interface between the support structures and the first dental aligner to remove the one or more support structures from the first dental aligner. ### Claim 9 (depends on 8) The system of claim 8, wherein: the one or more support structures includes a continuous support that extends a length along a portion of a surface of the first dental aligner; the length is greater than 0.35 millimeters; and cutting the interface includes making a continuous cut along the length of the continuous support. ### Claim 10 (depends on 8) The system of claim 8, wherein printing the first dental aligner includes: printing, by the 3D printing fabrication system, the first dental aligner layer-by-layer at an angle relative to normal of a surface; and wherein the angle is in a range of 5 degrees to 45 degrees relative to the normal of the surface. ### Claim 11 (depends on 10) The system of claim 10, wherein adding the one or more support structures to the first digital model to be formed with the first dental aligner is based on at least one of the angle of the first dental aligner relative to the normal or a position of the one or more support structures relative to the first dental aligner. ### Claim 12 (depends on 8) The system of claim 8, wherein: the one or more features of the first dental aligner includes at least one of a fiducial, a data matrix, or a readable indicium; and the one or more features are positioned on at least one support structure of the first dental aligner. ### Claim 13 (depends on 10) The system of claim 10, wherein the one or more support structures are coupled to at least one of an occlusal surface of the first dental aligner or an edge of the first dental aligner. ### Claim 14 A system, comprising: a fabrication computing system having one or more processors and memory storing instructions that, when executed by the one or more processors, cause the one or more processors to: receive a first digital model of a first dental aligner configured to move one or more teeth based on a generated treatment plan; receive a second digital model of a second dental aligner configured to move one or more teeth based on a second generated treatment plan; prepare the first digital model of the first dental aligner for manufacturing, wherein preparing the first digital model of the first dental aligner includes modifying the first digital model by adding one or more support structures to the first digital model to be formed with the first dental aligner; and prepare the second digital model of the second dental aligner for manufacturing, wherein preparing the second digital model of the second dental aligner includes analyzing a size or shape of the second digital model of the second dental aligner and a size or shape of the first digital model of the first dental aligner; and a 3D printing fabrication system configured to print the first dental aligner with the one or more support structures and the second dental aligner simultaneously. ### Claim 15 (depends on 14) The system of claim 14, wherein: the one or more support structures includes a continuous support that extends a length along a portion of a surface of the first dental aligner; and the length is greater than 0.35 millimeters. ### Claim 16 (depends on 14) The system of claim 14, wherein printing the first dental aligner includes: printing, by the 3D printing fabrication system, the first dental aligner layer-by-layer at an angle relative to normal of a surface; and wherein the angle is in a range of 5 degrees to 45 degrees relative to the normal of the surface. ### Claim 17 (depends on 16) The system of claim 16, wherein adding the one or more support structures to the first digital model to be formed with the first dental aligner is based on the angle of the first dental aligner relative to the normal. ### Claim 18 (depends on 16) The system of claim 16, wherein modifying the first digital model by adding the one or more support structures to the first digital model to be formed with the first dental aligner includes: determining an attachment position of the one or more support structures relative to the first dental aligner based on the angle; and wherein the attachment position includes at least one of an occlusal surface or an edge of the first dental aligner. ### Claim 19 (depends on 14) The system of claim 14, wherein: the one or more support structures includes a plurality of support structures; and a first support structure of the plurality of support structures is positioned along an edge of the first dental aligner and a second support structure of the plurality of support structures is positioned towards a center of the first dental aligner. ### Claim 20 (depends on 14) The system of claim 14, wherein the one or more support structures are configured to be removed by a laser.