Orthodontic aligner manufacturing and quality assessment system

A method of manufacturing an orthodontic aligner, comprising:

• receiving, at a holder, a feature of the orthodontic aligner, the feature comprising a first surface having a first shape, wherein the holder holds the feature of the orthodontic aligner at a reference position;
• determining an aligner type of the orthodontic aligner, wherein determining the aligner type comprises:
• capturing an image of the feature;
• and
• inputting the image into a trained machine learning model, wherein the trained machine learning model outputs a classification for the orthodontic aligner that indicates the aligner type;
• determining an object type to use from a plurality of object types, wherein the object type is associated with the aligner type;
• automatically picking up an object having the object type using a robot arm;
• automatically placing the object against the feature at the reference position using the robot arm, wherein the object comprises a second surface having a second shape that mates with the first shape;
• applying pressure to press the object against the feature of the orthodontic aligner;
• and
• bonding the object to the feature of the orthodontic aligner while applying the pressure.

A method of manufacturing a dental appliance, comprising:

• receiving, at a holder, a feature of the dental appliance, the feature comprising a first surface having a first shape, wherein the holder holds the feature of the dental appliance at a reference position;
• automatically placing an object against the feature at the reference position using a robot arm, wherein the object comprises a second surface having a second shape that mates with the first shape;
• capturing an image of the dental appliance in the holder prior to bonding the object to the dental appliance;
• processing the image;
• determining whether the object is correctly placed against the feature of the dental appliance based on a result of the processing;
• applying pressure to press the object against the feature of the dental appliance;
• and
• bonding the object to the feature of the dental appliance while applying the pressure.

A method of manufacturing a dental appliance, comprising:

• receiving, at a holder, a feature of the dental appliance, the feature comprising a first surface having a first shape, wherein the holder holds the feature of the dental appliance at a reference position;
• automatically placing an object against the feature at the reference position using a robot arm, wherein the object comprises a second surface having a second shape that mates with the first shape;
• measuring an amount of force applied to place the object against the feature of the dental appliance during the placing of the object against the feature of the dental appliance;
• determining whether the amount of force is between an upper force threshold and a lower force threshold;
• determining whether the object has been correctly placed against the feature of the dental appliance based on whether the amount of force is between the upper force threshold and the lower force threshold;
• applying pressure to press the object against the feature of the dental appliance;
• and
• bonding the object to the feature of the dental appliance while applying the pressure.

A method of manufacturing a dental appliance, comprising:

• receiving, at a holder, a feature of the dental appliance, the feature comprising a first surface having a first shape, wherein the holder holds the feature of the dental appliance at a reference position;
• manufacturing an object comprising a second surface having a second shape that mates with the first shape, wherein the second surface of the object that mates with the first surface of the feature has a first average surface roughness that causes the second surface to have a target wettability, and wherein a third surface of the object that does not contact the dental appliance has a second average surface roughness that is lower than the first average surface roughness, wherein the second average surface roughness reduces at least one of absorbance or reflectance of the object to light;
• coating the second surface of the object with a bonding layer, wherein the first average surface roughness facilitates an even coating of the bonding layer on second surface;
• automatically placing the object against the feature at the reference position using a robot arm;
• applying pressure to press the object against the feature of the dental appliance;
• and
• bonding the object to the feature of the dental appliance while applying the pressure.

A method of manufacturing a clear plastic dental appliance, comprising:

• manufacturing an object configured to fit into a cavity of a clear plastic dental appliance, wherein the cavity comprises a first surface having a first shape, wherein the object comprises a second surface having a second shape that mates with the first surface of the cavity and that has a first average surface roughness that causes the second surface to have a target wettability, and wherein a third surface of the object that does not contact the clear plastic dental appliance has a second average surface roughness that is lower than the first average surface roughness, wherein the second average surface roughness reduces at least one of absorbance or reflectance of the object to coherent light used to perform laser welding;
• coating the second surface of the object with a photo-thermal compound, wherein the first average surface roughness facilitates an even coating of the photo-thermal compound on the second surface;
• disposing the object within the cavity of the clear plastic dental appliance;
• applying pressure to press the object against the cavity of the clear plastic dental appliance;
• and
• laser welding the object to the cavity of the clear plastic dental appliance while applying the pressure.