System to manufacture custom orthodontic appliances, program product, and related methods

A system to manufacture orthodontic appliances, the system comprising:

• a numerical control data processor defining a controller having memory and control program product stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of deriving a numerical control signal carrying electrical discharge device control instructions to form a bracket slot in a bracket of an orthodontic appliance and to separate the bracket from a runner connected to the bracket;
• and
• an electrical discharge device in communication with the controller and having an electrical discharge electrode assembly including an electrode and having at least one drive section adapted to position the bracket in electrical discharge contact with the electrode responsive to the numerical control signal to form the bracket slot and to separate the bracket from the runner when forming the bracket slot.

A system to manufacture orthodontic appliances, the system comprising:

• a controller having memory, data communication program product stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of receiving electrical discharge device control instructions describing a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance, and control program product also stored in the memory including instructions that when executed by the controller cause the controller to perform the operation of deriving a control signal carrying the electrical discharge device control instructions responsive to the electrical discharge device control instructions;
• and
• an electrical discharge device in communication with the controller having an electrical discharge electrode assembly including an electrode and having at least one drive section adapted to position the bracket in electrical discharge contact with the electrode responsive to the control signal to form the bracket slot according to a predefined electrical discharge cutting pattern derived to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire.

A method of manufacturing orthodontic appliances, the method comprising the steps of:

• deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute an electrical discharge cutting pattern extending along a perimeter of the bracket slot and configured to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire;
• and
• executing the electrical discharge cutting pattern responsive to the control signal to form the bracket slot.

A method of manufacturing orthodontic appliances, the method comprising the steps of:

• deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute an electrical discharge cutting pattern extending along a perimeter of the bracket slot and configured to substantially match associated dimensions of an archwire to thereby form a precision interface with the archwire, the bracket slot having a closed perimeter to thereby define a bracket tube;
• and
• executing the electrical discharge cutting pattern responsive to a control signal to form the bracket tube.

A method of manufacturing orthodontic appliances, the method comprising the steps of:

• deriving a control signal carrying device control instructions from a virtual dimensional representation of a bracket slot in a bracket of an orthodontic appliance describing operations to execute a machining cutting pattern extending along a perimeter of the bracket slot to form the bracket slot, the bracket slot having an open surface end and a closed base end and two spaced-apart sides extending therebetween;
• and
• executing the machining cutting pattern responsive to a control signal.

A method of manufacturing orthodontic appliances, the method comprising the steps of:

• deriving a control signal carrying device control instructions describing operations to execute a machining cutting pattern to separate a bracket of an orthodontic appliance from a runner connected thereto;
• and
• executing the machining cutting pattern responsive to the control signal.