Orthodontic appliance systems and methods of making same

A method of manufacturing a template for use in orthodontic treatment of a patient's teeth, the method comprising:

• providing a mold of the patient's teeth, the mold having at least one projection in the shape of at least one of the patient's teeth;
• securing an attachment to the at least one projection;
• forming a worksheet over the at least one projection and over the attachment to form a deformed area in the worksheet, the deformed area having a plurality of walls defining at least one cavity configured to receive the patient's tooth and a receptable;
• and
• removing the worksheet from the at least one projection with the at least one attachment being retained in the receptacle.

A method of manufacturing an orthodontic appliance system for use in orthodontic treatment of a patient, the method comprising:

• constructing a scaffold assembly including a base, one or more pillars and/or spars extending from the base, and an attachment extending from the one or more pillars and/or spars;
• placing a template in contact with the scaffold assembly, the template including a first shell with at least one cavity configured to receive a tooth, the first shell having a plurality of walls defining the at least one cavity, the plurality of walls being configured to conform to at least portions of one or more surfaces of the tooth, at least one of the plurality of walls includes a receptacle that is open to the at least one cavity, wherein placing includes inserting the attachment into the receptacle;
• and
• separating the attachment from the one or more pillars and/or spars, wherein during separating, the attachment remains coupled to the template in the receptacle.

A method of manufacturing an orthodontic appliance system for use in orthodontic treatment of a patient, the method comprising:

• providing a mold of the patient's teeth, the mold having at least one projection in the shape of at least one of the patient's teeth, the at least one projection including a through-passage;
• placing a container of dental composite in fluid communication with the through-passage;
• placing a template over the at least one projection, the template including a shell with at least one cavity configured to receive a tooth, the shell having a plurality of walls defining the at least one cavity, the plurality of walls being configured to conform to at least portions of one or more surfaces of the tooth, at least one of the plurality of walls includes a receptacle that is open to the at least one cavity, wherein placing includes positioning the receptacle in alignment with the through-passage;
• injecting dental composite from the container through the through-passage and into the receptacle;
• and
• removing the template from the at least one projection with the filled receptacle.