Method of Manufacturing A Dental Restoration Part

Abstract

A method for manufacturing a dental restoration part according to patient-specific requirements is provided, which dental restoration part comprises a prosthesis base, wherein the prosthesis base carries at least one prefabricated artificial tooth, in particular a large number of prefabricated artificial teeth.

It is also intended for the prosthesis base to have a surface on the side facing away from the prefabricated artificial teeth, i.e. on the side opposite thereof, and a three-dimensional layer of material to be applied to this surface of the prosthesis base using a three-dimensional additive method, by which the prosthesis base will be fabricated according to the patient-specific specifications.

Claims

1. A method for manufacturing a dental restoration part according to patient-specific specifications comprising providing a prosthesis base having one or more prefabricated artificial teeth, wherein the prosthesis base has a surface at a side facing away from the prefabricated artificial teeth, and applying three-dimensional layer-by-layer material application onto the surface of the side facing away from the prefabricated artificial teeth using a three dimensional additive process, wherein the material application onto the prosthesis base is produced according to the patient-specific specifications.

2. The method according to claim 1, wherein the surface at a side facing away from the one or more prefabricated artificial teeth is a surface opposite to the one or more prefabricated artificial teeth, and wherein the one or more prefabricated artificial teeth comprises a plurality of prefabricated artificial teeth.

3. The method according to claim 1, wherein the surface of the prosthesis base facing away from the prefabricated artificial teeth is a flat surface.

4. The method according to claim 1, wherein the additive process is a 3D printing process or stereolithography.

5. The method according to claim 1, wherein the layer-by-layer material application uses a CAD/CAM device such that the three-dimensional shape produced by the material application corresponds to a negative image of a patient's alveolar ridge.

6. The method according to claim 1, wherein, prior to layer-by-layer application of material to the surface of the prosthesis base facing away from the prefabricated artificial teeth, said surface is prepared by roughening, grooving or structuring, to create an enlarged effective surface.

7. The method according to claim 1, further comprising pretreating the surface facing away from the prefabricated artificial teeth with a primer prior to layer-by-layer application of material onto the surface of the prosthesis base facing away from the prefabricated artificial teeth.

8. The method according to claim 1, wherein the prosthesis base comprises a material which can be thermally and plastically deformed by the action of heat.

9. The method according to claim 8, wherein the shape of the plastically deformed prosthesis base is optically detected to provide prosthesis base data and wherein said data is transmitted to a CAD/CAM device.

10. The method according to claim 1, wherein reference points of the prosthesis base comprising X and Y coordinates of one or more prefabricated artificial teeth are detected and the artificial teeth data is transmitted to a CAD/CAM device.

11. The method according to claim 1, wherein the material to be applied layer-by-layer onto the prosthesis base comprise acrylates, methacrylates or a mixture thereof.

12. The method according to claim 1, wherein the material to be applied layer-by-layer onto the prosthesis base is monochrome.

13. The method according to claim 1, wherein the material to be applied layer-by-layer onto the prosthesis base in color corresponds to the material color of the prosthesis base.

14. A prefabricated product for a dental restoration part comprising a prosthesis base, wherein the prosthesis base carries one or more prefabricated artificial teeth, wherein the prosthesis base has a blank prefabricated surface at a side opposite to the prefabricated artificial teeth, which blank surface may be further modified to provide a patient-specific surface thereon.

15. The prefabricated product according to claim 14, wherein the prosthesis base including the prefabricated surface is produced using an additive, a subtractive or a pressing technique.

16. A dental restoration part produced from a prefabricated product comprising a prosthesis base, wherein the prosthesis base carries one or more prefabricated artificial teeth on one side and having a blank surface on a side opposite the one side with the artificial teeth, wherein the blank surface is provided with additional layers of material to provide a prosthesis base having a patient-specific surface.

17. The dental restoration part according to claim 16, wherein the one or more prefabricated artificial teeth comprise a plurality of prefabricated artificial teeth or a continuous tooth rim, wherein the patient-specific surface comprises an additive finalized surface, and wherein the side facing away from the one or more prefabricated artificial teeth is at a side opposite from the prefabricated artificial teeth.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Further advantages, details and features will arise from the following description of an exemplary embodiment of the invention while making reference to the drawings, wherein

[0024] FIG. 1a-c is a schematic illustration of the prosthesis base body according to the invention,

[0025] FIG. 2 illustrates material application using the three-dimensional additive method,

[0026] FIG. 3 is a sectional view of the prosthesis base according to the invention following completion using the method of FIG. 2, and

[0027] FIG. 4 is a schematic representation of the computer-controlled material application of prosthetic material.

DETAILED DESCRIPTION

[0028] FIG. 1a shows a strongly schematic prosthesis base body 10. A dental arch 12, consisting of several artificial teeth, is glued into the base body 10. The material 20 of the prosthesis base body completely surrounds the dental arch 12 at its tooth necks. Opposite to the dental arch 12 the surface 14 is located, which, in this embodiment, is approximately flat.

[0029] In FIG. 1b, the surface 14 is provided comprising grooves, in FIG. 1c it is provided comprising a rather strongly structured surface, in this case a cross-shaped structure. In addition to the structures shown herein, the surface 14 may of course also be treated by any other surface treatment, such as roughening, increasing the effective surface area of surface 14 and thus improving adhesion of the surfaces to be applied according to the invention.

[0030] FIG. 2 shows how the material 22, e.g. acrylates or methacrylates, is applied to the surface 14 by a dispensing device 24 using the method according to the invention. In FIG. 2, thickness of material application is illustrated in a clearly overstated manner for better clarity.

[0031] The dispensing device 24 is controlled by the CAM device 30, schematically shown in FIG. 4, and recurrently travels in a grid-like manner across the surface 14, which is indicated by the double arrow 36, dispensing material depending on the data 32 provided by the CAD device 34. Material output which is activated or deactivated depending on the data 32 and the actual grid position of the output device 24 results in a 3D structure that corresponds to the negative shape of the patient's alveolar ridge, which has previously been captured by a 3D scanning process.

[0032] In FIG. 3, a sectional view is shown, with the section running across the prosthesis base starting from a molar 26 to a molar 28 opposite thereto. In this illustration it may readily be seen, how the individual artificial teeth 26, 28 are received in the material 20 of the prosthesis base body. The teeth 26, 28 are fixed thereto using a suitable adhesive. In FIG. 3, above the surface 14, the contour of the prosthesis base created by applying the layers of material 22 according to the invention, is shown very clearly.

[0033] By using a standard base body in combination with the 3D material application method, it is possible very easily to manufacture prostheses comprising a patient-specific prosthesis base with a high accuracy of fit and correspondingly high wearing comfort which meet high aesthetic requirements on the one hand, and on the other hand may still be fabricated with comparatively little expenditure in time and effort.