Custom orthodontic brackets and bracket forming method and apparatus

A method of forming sets of custom orthodontic brackets each including a base having a mounting surface connectable to a crown surface of one of the teeth of the patient, an archwire support extending from the base opposite the mounting surface, and an archwire slot formed in the support at a slot position and orientation relative to the mounting surface, the method comprising the steps of:

• (a) providing a workpiece holder configured to simultaneously support a plurality of orthodontic brackets, each at a respective workpiece position on the holder;
• (b) providing a computer controlled workpiece forming device operable to form brackets supported on the holder each with slot having a slot position and orientation relative to the mounting surface of the bracket;
• (c) storing digital data of the locations of each of the workpiece positions on the holder;
• then
• (d) producing digital information records, from digitized data of the shapes of the separate teeth of the patient and of finish positions ideal for the teeth of the patient, of the slot positions and orientations, relative to the respective mounting surface of each bracket of the plurality, for a slot in the support effective to enable an archwire mounted in the slots of the brackets of a set when mounted at bracket mounting locations on the teeth of the patient, to move the teeth to the finish positions ideal for the patient;
• (e) mounting each bracket of a set at a respective workpiece position on the holder,
• (f) generating a control signal containing information of the slot position and orientation, relative to the mounting surface, of the slot of each bracket;
• (g) positioning and orienting the device, in response to the control signal and relative to each respective workpiece position based on the stored digital data of the locations thereof, and moving the device relative to the workpiece positions to sequentially form each bracket with the slot thereof at the respective slot position and orientation in the support.

A method of forming sets of custom orthodontic brackets for custom orthodontic appliances, one for each of a plurality of individual patients, where a plurality of brackets of each set includes a base having a mounting surface connectable to a crown surface of one of the teeth of the patient, an archwire support extending from the base opposite the mounting surface, and an archwire slot formed in the support at a position and orientation relative to the mounting surface, the method comprising the steps of:

• (a) providing a workpiece holder configured to support orthodontic brackets thereon;
• (b) providing a computer controlled workpiece forming device positioned and oriented relative to the holder and operable to form each of a plurality of brackets when supported on the holder with slot having a predetermined position and orientation relative to the mounting surface thereof;
• (c) producing for each of a plurality of patients digital information records, from digitized data of the shapes of the separate teeth of the patient and of finish positions ideal for the teeth of the patient, of the slot positions and orientations, relative to the respective mounting surface of the respective bracket of the plurality, for a slot in the support of each bracket effective to enable an archwire mounted in the slots and the brackets of a set when mounted at predetermined locations on the teeth of the patient, to move the teeth of the patient to the finish positions ideal for the patient;
• (d) mounting each bracket of a first set at a bracket mounting position on the holder,
• (e) generating a control signal containing information of the slot position and orientation, of the slot of each bracket of the first set, relative to the mounting surface of the bracket;
• (f) in response to the control signal, sequentially for each bracket of the first set:
• (1) moving the device relative to the bracket mounting position of the bracket on the holder to sequentially form the bracket having a slot at the respective slot position and orientation in the support thereof, and
• (2) repositioning and reorienting the device relative to the bracket mounting position for a next bracket, until each bracket of the first set is formed for an custom appliance for the first patient;
• (g) mounting each bracket of a second set at the bracket mounting position therefor on the holder,
• (h) generating the control signal containing information of the slot position and orientation, of the slot of each bracket of the second set, relative to the mounting surface of the bracket;
• (i) in response to the control signal, sequentially for each bracket of the second set:
• (1) moving the device relative to the bracket mounting position of the bracket on the holder to sequentially form the bracket having a slot at the respective slot position and orientation in the support thereof, and
• (2) repositioning and reorienting the device relative to the bracket mounting position for a next bracket, until each bracket of the second set is formed for an custom appliance for the second patient.