Transfer apparatus for orthodontic appliances and related methods of manufacturing

A physical mockup for creating a transfer apparatus, the mockup comprising:

• a representation of at least a portion of a dental arch, the dental arch including a plurality of teeth, each tooth including an occlusal surface, a lingual surface, and a labial surface;
• wherein one or more teeth include an alignment pin projecting upward from the occlusal surface;
• an appliance carrier on each alignment pin of the one or more alignment pins, the appliance carrier comprising;
• a crane including a crane body having a tooth-facing surface, the facing surface configured to be arranged above but configured to not contact the occlusal surface of the tooth,
• the orthodontic appliance, the appliance including a base for bonding the appliance to the tooth and a body including a perimeter;
• and
• one or more coupling arms configured to connect the crane to the appliance, wherein the coupling arms are frangible between the crane and the appliance.

A method for creating a transfer tray for one or more orthodontic appliances, the method comprising:

• providing a physical mockup comprising:
• a representation of at least a portion of a dental arch, the dental arch including a plurality of teeth, each tooth including an occlusal surface, a lingual surface, and a labial surface;
• wherein one or more teeth include an alignment pin projecting upward from the occlusal surface;
• installing, for each tooth including an alignment pin, an appliance carrier on the alignment pin, the carrier comprising:
• a crane including a crane body having a tooth-facing surface, the facing surface configured to be arranged above but not contact an occlusal surface of the tooth when the transfer body is installed on the dental arch,
• the orthodontic appliance, the appliance including a base for bonding the appliance to the tooth and a body including a perimeter;
• one or more coupling arms configured to connect the crane to the appliance, wherein the coupling arms are frangible between the crane and the appliance;
• and
• forming a tray over the mockup and the carrier.