Prefabricated components for dental appliances

A method of making a ready-to-use component for a dental appliance comprising:

• preparing a mold for the desired shape of the component;
• wherein the mold comprises at least a first and a second section;
• placing a first amount of composite material into the first section;
• curing or partially curing the composite material;
• placing a second amount of composite material into the first and second sections;
• curing the second amount of composite material in the first section, whereby the second amount of composite material in the second section remains uncured;
• covering the uncured second section with a protective cover to prevent curing until use.

A method of making a dental restoration for direct application into a patient's mouth comprising:

• providing a ready-to-use component comprising two or more sections of prefabricated preshaped fiber-reinforced composite material comprising a polymeric matrix and a reinforcing fiber component wherein at least one of the two or more sections is cured to a hardness for use in the dental appliance system, wherein at least one of the two or more sections is uncured;
• and wherein the at least one uncured section is covered with a protective cover;
• applying a bonding agent to one or more of the patient's teeth proximate an area for insertion of the ready-to-use component;
• removing the protective cover from the at least one uncured section;
• inserting the ready-to-use component in the patient's mouth and bonding the at least one uncured sections to the one or more of the patient's teeth to provide a dental restoration.

A method of making a dental restoration for indirect application into a patient's mouth comprising:

• providing a ready-to-use component comprising two or more sections of prefabricated preshaped fiber-reinforced composite material comprising a polymeric matrix and a reinforcing fiber component wherein at least one of the two or more sections is cured to a hardness for use in the dental appliance system, wherein at least one of the two or more sections is uncured;
• and wherein the at least one uncured section is covered with a protective cover;
• applying a bonding agent to one or more of the patient's teeth proximate an area for insertion of the ready-to-use component;
• removing the protective cover from the at least one uncured section;
• inserting the ready-to-use component in the patient's mouth and bonding the at least one uncured sections to the one or more of the patient's teeth to provide a dental restoration the patient's mouth.

A ready-to-use component in the fabrication of a dental appliance system comprising:

• a one-piece hybrid component having at least one cured section and at least one uncured section;
• wherein the cured section comprises a first layer of fiber-reinforced composite material, a second layer of fiber-reinforced composite material, and a third layer of filled composite material;
• and
• wherein the second layer of fiber-reinforced composite material extends into the at least one uncured section.

A ready-to-use component in the fabrication of a dental appliance system comprising:

• a one-piece hybrid component having at least one cured section and at least one uncured section;
• wherein the cured section comprises a first layer of filled composite material, a second layer of fiber-reinforced composite material, and a third layer of filled composite material;
• and
• wherein the second layer of fiber-reinforced composite material extends into the at least one uncured section.

A ready-to-use component in the fabrication of a dental appliance system comprising:

• a one-piece hybrid component having at least one cured section and at least one uncured section;
• wherein the cured section comprises a first layer of fiber-reinforced composite material, a second layer of fiber-reinforced composite material, and a third layer of fiber-reinforced composite material;
• and
• wherein the second layer of fiber-reinforced composite material extends into the at least one uncured section.