METHOD FOR GENERATING A PARTIALLY-CURED ITEM, A PARTIALLY-CURED ITEM AND A CURED OBJECT

Abstract

The invention relates to a method for partial curing of an initial photoreactive material for 3D printing, comprising the steps of:

a) providing an item (1) comprising the initial photoreactive material for 3D printing,

b) a partial irradiation step comprising irradiating at least one curing section (20) of the initial photoreactive material for 3D printing of the item with a curing irradiation, yielding at least one cured section (120) of a partially-cured item (10), and at least one semi-curing section (40) of the initial photoreactive material of the item is irradiated with a semi-curing irradiation, yielding at least one semi-cured section (140) of the partially-cured item.

Claims

1. A method for partial curing of an initial photoreactive material for 3D printing, comprising the steps of: a) providing an item (1) comprising the initial photoreactive material for 3D printing, b) a partial irradiation step comprising irradiating at least one curing section (20) of the initial photoreactive material for 3D printing of the item with a curing irradiation, yielding at least one cured section (120) of a partially-cured item (10), and at least one semi-curing section (40) of the initial photoreactive material of the item is irradiated with a semi-curing irradiation, yielding at least one semi-cured section (140) of the partially-cured item.

2. The method according to claim 1, characterised in that the at least one curing section (20) of the initial photoreactive material of the item is irradiated via a focused light beam, yielding at least one cured section (120) of the partially-cured item.

3. The method according to claim 1, characterised in that the at least one curing section (20) is irradiated for a curing duration and in that the at least one semi-curing section (40) is irradiated for a semi-curing duration, wherein the curing duration is longer than the semi-curing duration.

4. The method according to claim 1, characterised in that the at least one curing section (20) of the initial photoreactive material is exposed to a curing energy for a curing duration and the at least one semi-curing section (40) of the initial photoreactive material is exposed to a semi-curing energy for a semi-curing duration, such that a double bound turnover in the cured section is at least 2% larger than a double bound turnover in the semi-cured section.

5. The method according to claim 1, characterised in that the initial photoreactive material for 3D printing comprises a 3D printing resin, in particular a polymer resin, in particular a photopolymer resin, in particular a resin comprising at least one of an acrylate, a methacrylate and an epoxide.

6. A partially-cured item (10) comprising an initial photoreactive material for 3D printing comprising at least one cured section (120) and at least one semi-cured section (140), in particular generated according to claim 1, characterised in that a first deformation resistance which is the deformation resistance of the at least one cured section (120) is larger than a second deformation resistance which is the deformation resistance of the at least one semi-cured section (140).

7. The partially-cured item (10) according to claim 6, characterised in that second deformation resistance is less than 95% of the first deformation resistance, in particular less than 90% of the first deformation resistance, in particular in that the second deformation resistance is configured such that the semi-cured section (140) is deformable such that the semi-cured section (140) embeds a subject pressed in the semi-cured section (140).

8. The partially-cured item (10) according to claim 6, characterised in that the partially-cured item (10) comprises a partially-cured resin, in particular a partially-cured polymer resin, in particular a partially-cured photopolymer resin, in particular a partially-cured resin comprising at least one of an acrylate, a methacrylate and an epoxide.

9. The partially-cured item (10) according to claim 6, characterised in that the partially cured item (10) is a precursor (200) of a dental item, in particular one of a precursor of a full dental prosthesis, a partial dental prosthesis, a denture, a denture base, a drilling template, a gingival mask, and an occlusal splint.

10. A method for generating an object, comprising the steps of: a) providing a partially-cured item (10) comprising an initial photoreactive material for 3D printing comprising at least one cured section (120) and at least one semi-cured section (140), in particular generated according to claim 1, b) providing an insertion element (400) comprising at least one anchor section (410), c) inserting the insertion element (400) in the at least one semi-cured section (140) of the partially-cured item (10) such that the at least one semi-cured section (140) embeds the at least one anchor section (410).

11. The method according to claim 10, characterised in that the anchor section (410) directly contacts the initial photoreactive material for 3D printing.

12. The method according to claim 10, characterised in that before step c) an adhesive is applied on an adhesion section of the insertion element (400) and/or in that subsequent to step c) the method comprises the step of curing the at least one semi-cured section (140), yielding a cured object.

13. The method according to claim 10, characterised in that the at least one semi-cured section (140) is exposed to a curing energy.

14. A cured object comprising an insertion element comprising at least one anchor section (410) embedded in a cured initial photoreactive material for 3D printing, in particular generated according to claim 10, characterised in that the at least one anchor section (410) contacts the cured initial photoreactive material for 3D printing.

15. The object according to claim 14, characterised in that the cured object is a dental object, in particular one of a full dental prosthesis, a partial dental prosthesis, a denture base, a denture, a drilling template, a gingival mask, and an occlusal splint.

Description

[0084] In the following, further features, advantages and embodiments of the present invention are explained with reference to the Figures, wherein

[0085] FIG. 1 shows an item comprising a curing section and a semi-curing section,

[0086] FIG. 2 shows curing of the curing section,

[0087] FIG. 3 shows generation of a partially-cured item using a plurality of light sources,

[0088] FIG. 4A, FIG. 4B shows generation of a partially-cured item using a mirror,

[0089] FIG. 5 shows a side view of a partially cured item comprising a plurality of differently semi-cured layers,

[0090] FIG. 6 shows a side view of a partially cured item,

[0091] FIG. 7 shows a side view of a partially cured item,

[0092] FIG. 8 shows a side view of a partially cured item,

[0093] FIG. 9 shows a dental partially-cured item and an insertion element, and

[0094] FIG. 10A, FIG. 10B show a dental partially-cured item in that insertion elements are inserted.

[0095] FIG. 1 shows an item 3 comprising an initial photoreactive material 1 for 3D printing. The item 3 can comprise a curing section 20. Further, the item 3 can comprise a semi-curing section 40. The semi-curing section 40 can adjoin the curing section 20.

[0096] FIG. 2 illustrates the generation of a partially-cured item 10 by a curing of a curing section by means of a focused light beam 70. The focused light beam 70 can be emitted by a focussing light source 60. Due to the irradiation by the focused light beam 70, the initial photoreactive material 1 of the curing section is cured, generating a cured section 120.

[0097] In FIG. 3 an embodiment is illustrated in that an item is exposed by a curing light source 64 generating a cured section 120, and a semi-curing light source 65 yielding a semi-cured section 140, generating a partially-cured item 10.

[0098] In an embodiment, the curing light source 64 emits a light ray 74 with a curing wavelength, in particular, light with a curing energy h.Math.v.sub.c. The semi-curing light source 65 can emit a semi-curing light ray 75 with a semi-curing wavelength, in particular, light with a semi-curing energy h.Math.v.sub.s.

[0099] FIG. 4A and FIG. 4B show an embodiment of the method in that a mirror 500 directs a light ray 76, 76′, emitted by a light source 66. The light ray 76, 76′ can impinge the mirror 500 that can direct it towards the item 3. Depending on the position of the mirror 500, in particular a tilt in relation to the light source 66 and/or the item 3, the light ray 76, 76′ can be directed to the cured section 120 (FIG. 7A) or the semi-cured section (FIG. 7B).

[0100] By regulating the position of the mirror 500, for instance via a mirror regulation device 550, the curing duration and/or the semi-curing duration can easily be regulated.

[0101] FIG. 5, FIG. 6, FIG. 7 and FIG. 8 show side views of different embodiments of a partially-cured item 10.

[0102] The partially-cured item 10 can comprise a plurality of layers 600a, 600b, 600c, 600d, 600e. Each layer can be semi-cured by a different semi-curing energy h.Math.v.sub.s and/or for a different semi-curing duration such that each layer 600a, 600b, 600c, 600d, 600e can have a different hardness (indicated by the different shading FIG. 7).

[0103] A layer 600a can extend in an extension direction 650.

[0104] In an embodiment, each layer 600a, 600b, 600c, 600d, 600e can comprise a respective cured section 120a, 120b, 120c, 120d, 120e and a respective semi-cured section 140a, 140b, 140c, 140d, 140e. The semi-cured section 140a, 140b, 140c, 140d, 140e can be arranged such that they adjoin each other, generating a semi-cured section 140 that spans the partially-cured item 10. In particular, semi-cured section 140a, 140b, 140c, 140d, 140e of neighbouring layers 600a, 600b, 600c, 600d, 600e adjoin each other perpendicular to the extension direction 650 (FIG. 6, FIG. 7).

[0105] In an embodiment, the partially-cured item 10 comprises a plurality of semi-cured sections 140, 140′ (FIG. 7, FIG. 8). This means that a layer can 600b, 600c, 600d, 600e can comprise a plurality of semi-cured section 140b, 140c, 140d, 140e, 140′b, 140′c, 140′d, 140′e.

[0106] In FIG. 7, an embodiment is shown in that at least one layer 600a exists that comprises a number of semi-cured sections 140a, that differs from the number of semi-cured sections of at least one other layer 600b, 600c, 600d, 600e. In other word this means that a semi-cured section 140′ can be generated that extends into the partially-cured item 10 but that not span the partially-cured item 10.

[0107] In an embodiment, the layers 600a, 600b, 600c, 600d, 600e comprise a gap, such that the partially cured item 10 comprises a recess 15. The semi-cured sections 140b, 140c, 140d, 140e, 140′b, 140′c, 140′d of the layers can be positioned such that they border the recess 15 (FIG. 8).

[0108] FIG. 9 shows a sectional view of an embodiment of a partially-cured item 10 and of an embodiment of an insertion element 400. The partially cured item 10 can be a precursor of a dental object 200. It can comprise a cured section 120 and a semi-cured section 140. In an embodiment, the semi-cured section 140 is configured such that it is a coat 451 of a cavity 450 of the partially cured item 10.

[0109] The insertion element 400 can be an artificial tooth 402. The insertion element 400 can comprise an anchor section 410.

[0110] In an embodiment, the insertion element 400 can be moved along an insertion direction 320 such that the insertion element 400 is inserted in the semi-cured section 140, in particular in the cavity 450. The semi-cured section 140 can be soft, in particular the semi-cured section 140 can be adjustable, in particular the semi-cured section 140 can be gel-like. In an embodiment, the semi-cured section 140 can adapt when the insertion element 400 is inserted in the semi-cured section 140. In particular, the semi-cured section 140 can adapt such that it directly contacts the insertion element 400, in particular the anchor section 410.

[0111] Hence, in an embodiment, when semi-cured section 140 can adapt, the cavity 450 does not need to exactly fit to the anchor section 410 of the insertion element 400. The semi-cured section 140 can be deformed by the insertion element 400 during insertion and can then adapt and directly attach to the insertion element 400, in particular to the anchor element 410.

[0112] In FIG. 10A and 10B, a top view of a partially cured item 10 is shown in that a plurality of insertion elements 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′, are inserted. Each insertion element 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′ can be associated to each one respective semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′.

[0113] The partially cured item 10 can be a precursor of a dental item 200. In an embodiment, a semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ directly contacts the respective insertion element 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′. In other words this means that there is no gap between the semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ and the respective insertion element 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′. In other words this means that an insertion element 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′ is embedded by the respective semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′.

[0114] In an embodiment, the partially cured item 10 can be cured, in particular a semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ can be cured. When a semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ is cured, it can fix the respective insertion element 400, 400′, 400.sup.2′, 400.sup.3′, 400.sup.4′, 400.sup.5′, 400.sup.6′, 400.sup.7′, 400.sup.8′, 400.sup.9′, 400.sup.10′, 400.sup.11′, in particular the anchor section of the respective insertion element. In an embodiment, the curing of the semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ can provide a chemical association between the anchor section of an insertion element and the respective cured semi-cured section. In an embodiment, the curing of the semi-cured section 140, 140′, 140.sup.2′, 140.sup.3′, 140.sup.4′, 140.sup.5′, 140.sup.6′, 140.sup.7′, 140.sup.8′, 140.sup.9′, 140.sup.10′, 140.sup.11′ can provide a mechanical fixation of anchor section of an insertion element in the respective cured semi-cured section.

[0115] In an embodiment, the width and/or a length of the partially-cured item 10 is about 12 to 16 cm (FIG. 10A).