Automated method of manufacturing oral appliances

A method of manufacturing a splint for a mandibular advancement device, the method comprising the steps of:

• a) preparing a three-dimensional electronic model of a patient's dentition;
• b) superimposing an image of a solid block over the electronic model of one of the patient's upper or lower dentition,
• wherein the solid block has a “U” shape that approximates the curvature of the patient's dentition, and
• whereby a gingival surface of the solid block is at about a height of contour of a molar tooth of the dentition;
• d) determining the contour curve for the dentition, wherein a contour curve is placed at an offset distance at either a buccal or lingual side of the dentition, wherein the offset distance is between about 20% to about 80% of a visible tooth height of one of the posterior-most molars;
• e) moving the height of contour curve towards a gingival line by a distance of about between about 1% to about 50% of the visible tooth height of one of the posterior-most molars;
• f) subtracting the portion of the solid block below the height of contour curve to obtain a contoured block;
• g) subtracting the three-dimensional electronic model of the patient's dentition from the contoured block to obtain an appliance data set comprising data associated with a portion corresponding to an appliance accessory in or coupled to the oral appliance, a portion to attach the appliance accessory to the oral appliance, or a connection point to connect the appliance accessory, wherein the appliance accessory comprises an electronic chip or an electronic or microelectronic device;
• h) automatically manufacturing a dental appliance in accordance with the appliance data set.