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US 11,931,223 B2Granted
Cellular architecture for controlled focal stiffness across intraoral appliances
AssigneeAlign Technology, Inc.
InventorsYaser Shanjani, Jun Sato, Ryan Kimura
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Abstract
Described herein are intraoral appliances with adaptive cellular materials and structures to provide enhanced mechanical properties and orthodontic functionality, and related methods. The described appliances may have higher Young's modulus and elongation rate than appliances made from conventional materials. Further, the described appliances may have desirable non-linear force/strain profiles. Additionally, the control provided by using cellular structures allow for increased customization for individual patients. Thus, the described appliances may be more effective, have longer appliance lifetimes and/or provide less discomfort to patients.
Claims34
An A three-dimensionally (3D) printed aligner comprising:
- a plurality of additively manufactured layers;
- a 3D printed body comprising forming a plurality of tooth-receiving cavities shaped to receive and to reposition a corresponding plurality of a patient's dentition from a first arrangement toward a second arrangement, wherein all of the tooth-receiving cavities are formed only from the plurality of additively manufactured layers;
- a one or more interproximal areas integral to the 3D printed body, wherein the one or more interproximal areas form an interproximal region of at least two tooth-receiving cavities, the one or more interproximal areas composed of a first 3D printed cellular structure composed of the plurality of additively manufactured layers, wherein the first 3D printed cellular structure includes a first network of interconnected unit cells, the first network of interconnected unit cells having a first elongation characteristic corresponding to a first apparent Young's modulus within a range from 100 MPa to 5000 MPa, wherein the first 3D printed cellular structure has a porosity selected from a range from 25% to 75%, wherein the porosity is the volume of void space of the first 3D printed cellular structure divided by the volume of the first 3D printed cellular structure, and wherein the one or more interproximal areas comprise a non-linear force-strain profile comprising a force within a range from 5 N to 12.5 N over a strain within a range from 0.02 to 0.12;
- and
- a one or more remainder areas integral to the 3D printed body, wherein the one or more remainder areas form a remainder of the 3D printed body in view of the at least two tooth-receiving cavities, at least a portion of the one or more remainder areas being proximate to the one or more interproximal areas, the one or more remainder areas having a second elongation characteristic corresponding to a second apparent Young's modulus different from the first apparent Young's modulus.
2 more elements
A three-dimensionally (3D) printed aligner comprising:
- a plurality of additively manufactured layers;
- and
- a 3D printed body composed of the plurality of additively manufactured layers, wherein the 3D printed body comprises a plurality of tooth-receiving cavities shaped to receive and to reposition a corresponding plurality of a patient's dentition from a first arrangement toward a second arrangement, wherein all of the tooth-receiving cavities are formed only from the plurality of additively manufactured layers, wherein the 3D printed body comprises an adaptive cellular structure composed of 100 to 10,000 additively manufactured layers of the plurality of additively manufactured layers, and wherein the adaptive cellular structure includes a network of interconnected unit cells having a cell distribution providing a selected spatial distribution of at least one mechanical property along one or more physical dimensions of the 3D printed aligner,
- wherein the adaptive cellular structure is characterized by a porosity selected from a range from 25% to 75%, wherein the porosity is the volume of void space of the adaptive cellular structure divided by the volume of the adaptive cellular structure,
- wherein the adaptive cellular structure comprises a material having an apparent Young's modulus within a range from 100 MPa to 5000 MPa, and
- wherein the 3D printed body comprises a non-linear force-strain profile comprising a force within a range from 5 N to 12.5 N over a strain within a range from 0.02 to 0.12.
3 more elements
A method for positioning teeth of a subject, the method comprising:
- applying a three-dimensionally (3D) printed aligner to the teeth of the subject, the 3D printed aligner comprising:
- a plurality of additively manufactured layers;
- and
- a 3D printed body composed of the plurality of additively manufactured layers, wherein the 3D printed body comprises a plurality of tooth-receiving cavities shaped to receive and to reposition a corresponding plurality of the teeth of the subject from a first arrangement toward a second arrangement, wherein all of the tooth-receiving cavities are formed only from the plurality of additively manufactured layers, and wherein the 3D printed body comprises 100 to 10,000 additively manufactured layers of the plurality of additively manufactured layers forming an adaptive cellular structure comprising a network of interconnected unit cells having a heterogeneous cell distribution providing a selected spatially nonhomogeneous distribution of at least one mechanical property along one or more physical dimensions of the 3D printed aligner,
- wherein the adaptive cellular structure is characterized by a porosity selected from a range from 25% to 75%, wherein the porosity is the volume of void space of the adaptive cellular structure divided by the volume of the adaptive cellular structure, and
- wherein the adaptive cellular structure comprises a material having an apparent Young's modulus within a range from 100 MPa to 5000 MPa;
- and
- providing a selected distribution of forces to the teeth of the subject using the 3D printed aligner, thereby positioning the teeth of the subject, wherein the 3D printed aligner comprises a non-linear force-strain profile comprising a force within a range from 5 N to 12.5 N over a strain within a range from 0.02 to 0.12 when worn on the teeth of the subject.
5 more elements
Dependencies are inferred from the claim text.