A method of manufacturing and analyzing a quality of an orthodontic aligner is described. An orthodontic aligner is manufactured by printing a mold associated with a dental arch of a patient based on a digital model of the mold, forming an orthodontic aligner over the mold, and trimming the orthodontic aligner. A quality of the orthodontic aligner is then assessed by imaging the orthodontic aligner to generate a first digital representation of the orthodontic aligner, comparing the first digital representation of the orthodontic aligner to a digital file associated with the orthodontic aligner, determining whether a cutline variation is detected between the orthodontic aligner and the digital file, and determining whether there is a manufacturing defect of the orthodontic aligner based on whether the cutline variation exceeds a cutline variation threshold.

A method for manufacturing an orthodontic aligner includes printing a mold associated with a dental arch of a patient based on a digital model of the mold, forming the orthodontic aligner over the mold, and trimming the orthodontic aligner. The method further includes assessing a quality of the orthodontic aligner by receiving a digital representation of the orthodontic aligner, the digital representation having been generated based on imaging of the orthodontic aligner, analyzing the digital representation of the orthodontic aligner to identify a quality-related property of the orthodontic aligner, determining, based on the quality-related property, that the orthodontic aligner comprises a manufacturing flaw, and classifying the orthodontic aligner as requiring further inspection by a technician based on determining that the orthodontic aligner comprises the manufacturing flaw.

A method for manufacturing an orthodontic aligner includes printing a mold associated with a dental arch of a patient based on a digital model of the mold, forming the orthodontic aligner over the mold, and trimming the orthodontic aligner. The method further includes assessing a quality of the orthodontic aligner by receiving a digital representation of the orthodontic aligner, the digital representation having been generated based on imaging of the orthodontic aligner, analyzing the digital representation of the orthodontic aligner to identify a quality-related property of the orthodontic aligner, determining, based on the quality-related property, that the orthodontic aligner comprises a manufacturing flaw, and classifying the orthodontic aligner as requiring further inspection by a technician based on determining that the orthodontic aligner comprises the manufacturing flaw.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

Methods, systems, and apparatus, including computer programs stored on a computer-readable storage medium, for performing hybrid additive manufacturing. In some implementations, a hybrid additive manufacturing system causes a three-dimensional printer to print a sheet of material that includes printed features on one side of the sheet, each printed feature having a structural characteristic that is different from structural characteristics of a majority of the sheet. The system causes a molding machine to form the sheet using a mold, where at least one printed feature corresponds with an area of the mold at which the sheet deforms while being formed.

Methods, systems, and apparatus, including computer programs stored on a computer-readable storage medium, for performing hybrid additive manufacturing. In some implementations, a hybrid additive manufacturing system causes a three-dimensional printer to print a sheet of material that includes printed features on one side of the sheet, each printed feature having a structural characteristic that is different from structural characteristics of a majority of the sheet. The system causes a molding machine to form the sheet using a mold, where at least one printed feature corresponds with an area of the mold at which the sheet deforms while being formed.

A thermoplastic forming tool includes a wand that includes a handle, a tip, and a conduit coupling the handle to the tip. The tip includes a heating element, a forming shoe, and a forming shoe support. During use, heat from the heating element heats the forming shoe to a temperature at or above the glass transition temperature of a thermoplastic polymer. The thermoplastic forming tool may be used to apply a thermoplastic material to a surface.

A method of manufacturing and analyzing a quality of an orthodontic aligner is described. An orthodontic aligner is manufactured by printing a mold associated with a dental arch of a patient based on a digital model of the mold, forming an orthodontic aligner over the mold, and trimming the orthodontic aligner. A quality of the orthodontic aligner is then assessed by imaging the orthodontic aligner to generate a first digital representation of the orthodontic aligner, comparing the first digital representation of the orthodontic aligner to a digital file associated with the orthodontic aligner, determining whether a cutline variation is detected between the orthodontic aligner and the digital file, and determining whether there is a manufacturing defect of the orthodontic aligner based on whether the cutline variation exceeds a cutline variation threshold.

The present invention relates to a method for measuring (100) the thickness of devices (20) obtained by thermoforming a sheet of thermoplastic material on a positive mold (10). In particular, the present invention relates to a method for measuring the thickness of orthodontic dental devices obtained by thermoforming processes, such as orthodontic braces for incremental dental repositioning, bites, occlusal guides and so on, which comprises the steps consisting in acquiring (110) a plurality of images of the device (20) obtained by thermoforming in configuration fitted on the positive mold (10) and deriving therefrom a three-dimensional digital model of the assembly consisting of the positive mold (10) and the device (20) obtained by thermoforming fitted on the same (10); acquiring (120) a plurality of images of the positive mold (10) in the absence of the fitted thermoformed device (20) and deriving therefrom a three-dimensional digital model of the positive mold (10) alone; comparing (130) the two three-dimensional digital models derived and calculating thicknesses of the thermoformed device (20) on the basis of the differences detected by the comparison.