Common Placement Support for Artificial Teeth

Abstract

Computer implemented methods and user interfaces for facilitating the design of a so-called copy denture, whereby an existing denture is reproduced after making changes to the existing denture to improve fit, aesthetics or other parameters. A method may include the steps of obtaining a digital model of an existing denture, segmenting the digital model of the existing denture into an intermediate denture base model and at least one intermediate denture teeth model, and generating a digital data file of a final denture base model based on the intermediate denture base model and providing a digital data file of at least one final denture teeth model based on the at least one intermediate denture teeth model.

Claims

1. A computer implemented method for generating a digital model of a denture comprising a digital model of a denture base and at least one digital model of denture teeth, wherein the method comprises the steps of: obtaining a digital model of an existing denture; segmenting the digital model of the existing denture into an intermediate denture base model and at least one intermediate denture teeth model; and generating a digital data file of a final denture base model based on the intermediate denture base model and providing a digital data file of at least one final denture teeth model based on the at least one intermediate denture teeth model.

2. A computer implemented method according to claim 1, wherein the at least one intermediate denture teeth model includes at least two intermediate denture teeth models.

3. A computer implemented method according to claim 2, wherein the at least two intermediate denture teeth models include three intermediate denture teeth models.

4. A computer implemented method according to claim 1, wherein denture teeth in each of the at least one final denture teeth model are interproximally connected.

5. A computer implemented method according to claim 1, wherein a continuous recess is provided in the final denture base model for receiving one of the at least one final denture teeth model.

6. A computer implemented method according to claim 5, wherein the at least one final dental teeth model includes a plurality of final dental teeth model, and wherein the continuous recess is one of a plurality of continuous recesses provided in the final denture base model, each of the plurality of continuous recesses being configured to receive a corresponding one of the plurality of final denture teeth models.

7. A computer implemented method for generating a digital model of a denture comprising a digital model of a denture base and at least one digital model of denture teeth, wherein the method comprises, in sequence, the steps of: obtaining a digital model of a fitted existing denture; segmenting the digital model of the fitted existing denture into an intermediate denture base model and at least one intermediate denture teeth model; modifying the anatomy of the at least one intermediate denture base model; designing a coupling arrangement between the intermediate denture base model and the at least one intermediate denture teeth model, wherein the coupling arrangement comprises at least one recess formed in the intermediate denture base model and a protrusion extending from the at least one intermediate denture teeth model shaped to match the at least one recess; and generating a digital data file of a final denture base model based on the intermediate denture base model and generating a digital data file of at least one final denture teeth model based on the at least one intermediate denture teeth model.

8. A computer implemented method according to claim 8, wherein the step of obtaining a digital model of the fitted existing denture comprises scanning the fitted existing denture.

9. A computer implemented method according to claim 7, wherein the step of segmenting comprises segmenting each tooth of the fitted existing denture in the digital model of the fitted existing denture.

10. A computer implemented method according to claim 7, wherein the step of segmenting comprises segmenting a group of at least two teeth of the fitted existing denture in the digital model of the fitted existing denture.

11. A computer implemented method according to claim 7, wherein the step of modifying the anatomy of the at least one intermediate denture base model comprises sculpting a virtual papilla.

12. A computer implemented method according to claim 7, wherein the step of designing a coupling arrangement comprises providing a cement gap between the at least one recess and the corresponding protrusion in the shape of an offset between a digital model of the at least one recess and a digital model of the at least one protrusion.

13. A method for manufacturing a denture comprising the computer implemented method according to claim 7, further comprising providing the digital data file of the final denture base model and the digital data file of the at least one final denture teeth model to a 3D manufacturing process for manufacturing a denture base and at least one denture teeth and assembling the denture base and the at least one denture teeth by gluing.

14. A method for manufacturing a denture according to claim 13, wherein the 3D manufacturing process involves printing or milling.

15. A user interface presented on a digital monitor for grouping teeth models on a digital dental model, the user interface comprising a first user interface session including a rendering of the digital dental model in a first three dimensional workspace and a toolbar comprising at least one grouping button on the toolbar, wherein when activating the at least one grouping button at least one closed spline is generated enclosing at least one tooth at a boundary between at least one tooth model and a gingiva model of the digital dental model.

16. A user interface according to claim 15, wherein a plurality of grouping buttons are arranged in the toolbar and when activated each of the grouping button will provide one or more of the following actions: generate a plurality of closed splines, each spline enclosing one tooth model of the digital dental model; generate one closed spline enclosing all teeth models of the digital dental model; generate a plurality of closed splines, each spline enclosing a group of tooth models of the digital dental model; and/or prompting the user to select one or more tooth models of the digital dental model to be enclosed by a spline of the at least one closed spline.

17. A user interface according to claim 15, wherein the at least one tooth model is a denture teeth model and the digital dental model is a fitted existing denture model comprising the denture teeth model and a denture base model.

18. A user interface according to claim 15, further comprising a second user interface session comprising a rendering of the digital dental model in a second three dimensional workspace wherein the digital dental model is segmented into a denture base model and the at least one tooth model based on the at least one closed spline.

19. A user interface according to claim 18, wherein the digital dental model is segmented into the denture base model and the at least one tooth model based on the at least one closed spline, by using the at least one closed spline as a cutting spline to cut the digital dental model into the denture base model and the at least one tooth model.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0095] The above and/or additional objects, features and advantages of the present disclosure, will be further described by the following illustrative and non-limiting detailed description of embodiments of the present disclosure, with reference to the appended drawing(s), wherein:

[0096] FIG. 1 shows an example of a first user interface session of a scan session during a top side scan step of a method for building a digital design of a new denture;

[0097] FIG. 2 shows an example of a second user interface session of a scan session during a bottom side scan step of a method for building a digital design of a new denture;

[0098] FIG. 3 shows an example of a third user interface session involving merging during a method for building a digital design of a new denture;

[0099] FIG. 4 shows an example of a fourth user interface session during a teeth identification step of a method for building a digital design of a new denture;

[0100] FIG. 5 shows an example of a fifth user interface session during a segmentation step of a method for building a digital design of a new denture;

[0101] FIG. 6 shows an example of a sixth user interface session involving grouping during a method for building a digital design of a new denture;

[0102] FIG. 7 shows an example of a seventh user interface session during a first sculpting step of a method for building a digital design of a new denture;

[0103] FIG. 8 shows an example of an eighth user interface session during a second sculpting step of a method for building a digital design of a new denture;

[0104] FIG. 9 shows an example of a ninth user interface session during a coupling mechanism step of a method for building a digital design of a new denture;

[0105] FIG. 10 shows an example of a tenth user interface session during a coupling mechanism step of a method for building a digital design of a new denture;

[0106] FIG. 11 shows an example of an eleventh user interface session involving Boolean subtraction during a method for building a digital design of a new denture;

[0107] FIG. 12 shows an example of a twelfth user interface session involving model finalization during a method for building a digital design of a new denture;

[0108] FIG. 13 shows an embodiment of a denture comprising a denture base and artificial teeth with a common placement support as disclosed herein;

[0109] FIG. 14 shows a second embodiment of a denture comprising a denture base and artificial teeth with a common placement support as disclosed herein;

[0110] FIG. 15 shows a further embodiment of artificial teeth with common placement supports as disclosed herein;

[0111] FIG. 16 shows another embodiment of artificial teeth with a common placement support as disclosed herein;

[0112] FIG. 17 shows a schematic view of an embodiment of a system for executing the method for digital planning as disclosed herein; and

[0113] FIG. 18 shows a further embodiment of artificial teeth with a common placement support as disclosed herein.

DETAILED DESCRIPTION

[0114] In the following description, reference is made to the accompanying figures, which show by way of illustration how the disclosure may be practiced.

[0115] FIGS. 1-12 show examples of a method as disclosed herein wherein a fitted existing denture is used to build a digital design of a new denture which is ready to be manufactured using 3D printing or milling.

[0116] FIGS. 1-3 show how a digital model of a fitted existing denture can be obtained.

[0117] A first user interface session 1000 of a scan session is shown in FIG. 1. The occlusal side 10 of an existing denture 9 including teeth 12 has been scanned during a top side scan step 1001.

[0118] The occlusal side scan 10 is being trimmed in a trim step 1002 using trim tool 1003, such as a closed line 1004 for trimming.

[0119] After trimming of the occlusal side scan a gingiva side scan 11 from a scan session is provided in a second user interface session 1005 in a bottom side scan step 1006 as shown in FIG. 2.

[0120] An impression material 13 has been used in the existing denture 9 and used to do an impression of the patient's current gum surface in order to provide a fitted existing denture, which is the denture 9 being scanned as disclosed with respect to FIGS. 1 and 2.

[0121] Similar to the trim step 1002 of the occlusal side scan 10 a trim step 1007 is also performed where the gingiva side scan 11 is trimmed by a user.

[0122] Finally the occlusal side scan 10 and the gingiva side scan 11 are aligned in an alignment step 1008. In exemplary embodiments, this can be performed automatically seeing that the teeth 12 of the scans can be used as overlapping surfaces for alignment reference.

[0123] The aligned occlusal side scan 10 and gingiva side scan 11 are then merged into a digital model of the fitted existing denture 14 as shown in a third user interface session 1009 as shown in FIG. 3.

[0124] A segmentation process is subsequently initiated as shown in FIGS. 4-6.

[0125] FIG. 4 shows a fourth user interface session 1010 whereby each separate denture/artificial tooth 12 is identified on the digital model of the fitted existing denture 14 in a teeth identification step 1011.

[0126] Subsequent to the teeth identification 1011 a gum-tooth spline 15 is derived for each tooth 12 in segmentation step 1012 in a fifth user interface session 1013 shown in FIG. 5.

[0127] In the segmentation step 1012 the user can chose to group the teeth into groups by using grouping tools 1014 as shown in a sixth user interface session 1015 shown in FIG. 6. In the current case the user chooses to generate three groups which results in a first, second and third gum-tooth splines 16, 17 and 18 being generated. Each gum-tooth is a closed spline that defines the tooth boundary of a group of teeth.

[0128] Using the gum-tooth splines 16, 17 and 18 the digital model of the fitted existing denture 14 can be segmented into an intermediate denture base model 19, a first intermediate teeth model 20, a second intermediate teeth model 21 and a third intermediate teeth model 22 as shown in a seventh user interface session 1016 shown in FIG. 7.

[0129] FIGS. 7 and 8, showing the seventh user interface session 1016 and an eighth user interface 1017, which illustrates how the anatomies of the intermediate denture base model 19 and the intermediate teeth models 20, 21 and 22 can be modified in two sculpting steps 1019 and 1020. For example, the papillas 23 of the denture base in FIG. 8 have been accentuated by digitally modifying them using the sculpt toolkit 1018.

[0130] After the anatomies (outer visible surfaces) of the intermediate denture base model 19 and the intermediate denture teeth models 20, 21, 22 have been modified to provide a satisfactory result, a coupling mechanism is generated in a coupling mechanism step 1023 as shown in user interface session 1021 in FIG. 9 and user interface session 1022 in FIG. 10.

[0131] FIGS. 9 and 10 show the intermediate denture teeth models 20, 21 and 22 shown independently from the denture base. Protrusions 24, 25 and 26 are generated based on the respective gum-tooth border splines 16, 17 and 18. The protrusions extend below the anatomy of the teeth and do not need to be aesthetically correct.

[0132] In FIG. 9 the insertion direction 27 of the first intermediate denture teeth model 20 is determined and the protrusions 24 have been reduced in design compared to the protrusions 25 and 26 of the second and third intermediate denture teeth models 21 and 22.

[0133] Similarly, as shown in FIG. 10, the protrusions 25 and 26 of the second and third intermediate denture teeth models 21, 22 are designed similarly to the first protrusion 24. Also, the insertion direction 28 of the third intermediate denture teeth model 22 is determined. Seeing that the denture teeth are provided in groups as discussed above, different insertion directions can be provided which can be an advantage in order to reduce undercuts, and to improve aesthetics and stability of the final product.

[0134] Tools 1024 for designing the coupling setting, insertion direction and the like are provided in the ninth and tenth user interface sessions 1021 and 1022.

[0135] In the eleventh user interface session 1025 shown in FIG. 11 the intermediate denture teeth models 20, 21 and 22 are subtracted from the intermediate denture base model 19 using a Boolean subtraction. This creates first, second and third recesses 30, 31 and 32.

[0136] A pocket setting tool 1026 is provided in the user interface. This tool allows the user to determine a glue space which provides a small offset in the recesses to allow for gluing the manufactured denture base and teeth models together. Additionally, drill compensation can be selected, if the denture is to be manufactured by milling.

[0137] Finally, as shown in the twelfth user interface session 1027 in FIG. 12 all the models are finalized for production, providing a final denture base model 40, a first final denture teeth model 41, a second final denture teeth model 42 and third final denture teeth model 43.

[0138] These final models can then the shipped to a 3D manufacturing setup such as printing or milling manufacturing setups.

[0139] FIG. 13 shows the parts of a denture to yet assembled comprising a denture base 1, a set of 3D printed artificial teeth 2 connected to a common placement support 3.

[0140] The common placement support 3 is a result of the 3D printing process. Previously the common placement support 3 was removed right after manufacturing of the teeth, but by manufacturing the teeth in the desired relative arrangement the common placement support 3 is kept in order to keep the teeth in their arrangement during handling.

[0141] Accordingly, the teeth are placed in the recesses 4 in the denture base 1 and subsequently attached to the denture base 1, e.g., by gluing, with the common placement support connected to the teeth. This ensures optimal positioning of the teeth in the denture base and thereby achieving the desired occlusion of the final denture. When the glue has cured the common placement support can be removed.

[0142] In some situations, it is desired to have anterior teeth with improved esthetics, while the posterior teeth can have a simple finish as long as they are functional. FIG. 14 shows a denture base 200 wherein four anterior teeth 201 have been placed. The four anterior teeth have been placed separately and have a high esthetic finishing. The posterior teeth 202 have been printed and are all connected in a desired relative arrangement (determined during the digital design of the denture) via a common placement support 203.

[0143] The dental technician can easily place and glue the posterior teeth 202 in the respective recesses 204 in denture base 200 knowing that the correct arrangement and thereby occlusion is ensured. When the glue has cured the dental technician removes the common placement support.

[0144] FIGS. 13 and 14 illustrate how the common placement support is attached to the occlusal surfaces of the printed teeth. In alternative embodiments it may be advantageous to attach the common placement support to the lingual surface of the artificial teeth.

[0145] In one such embodiment as illustrated in FIG. 15 the artificial teeth 300 are separated into three groups 301, 302 and 303. The artificial teeth have been 3D printed and the respective printing sprues and support structures have been kept as common placement supports 304, 305 and 306.

[0146] As can be seen, the planning of the 3D printing is done so that the common placement supports are connected to the lingual side of the artificial teeth.

[0147] Similarly, in the embodiment in FIG. 16, there is provided a set of artificial teeth 400. This set of artificial teeth have been designed with a common placement support 401 connected to the lingual surface of the artificial teeth. In the embodiment in FIG. 16 the common placement support was designed in the digital design software (CAD) together with the artificial teeth and manufactured by milling.

[0148] FIG. 17 shows a schematic of a system suitable for digitally planning the manufacturing of the at least two digital artificial teeth as disclosed herein. The system 550 comprises a computer device 551 comprising a computer readable medium 552 and a processor 553. The system further comprises a visual display unit 556, a computer keyboard 554 and a computer mouse 555 for entering data and activating virtual buttons visualized on the visual display unit 556. The visual display unit 556 can be a computer screen. The computer device 551 is capable of receiving a digital 3D representation of the patient's jaw/oral cavity from a scanning device 557, such as the TRIOS intra-oral scanner manufactured by 3shape TRIOS, or capable of receiving scan data from such a scanning device and forming a digital 3D representation of the patient's jaw/oral cavity based on such scan data. The received or formed digital 3D representation can be stored in the computer readable medium 552 and provided to the processor 553. The processor 553 is configured for performing the steps of the method digitally planning method disclosed herein.

[0149] The system comprises a unit 558 for transmitting the at least two digital artificial teeth to e.g. a computer aided manufacturing (CAM) device 559, such as a milling machine or a 3D printer as disclosed.

[0150] Yet a further embodiment of a denture assembly 600 comprising a denture base 601 and artificial teeth 602 is shown in FIG. 18. The artificial teeth are provided as one unit via a common placement support 603 that connects all the artificial teeth. This ensures the relative position of the artificial teeth and facilitates easy placement of the teeth in the denture base 601.

[0151] The common placement support is provided such that it is visibly hidden when the artificial teeth are placed in the denture base 601. This is provided by designing the common placement support so that it is below the gingiva edge of the recess 604 when the artificial teeth are placed in the denture base.

[0152] Furthermore, to receive both the artificial teeth and the common placement support a single continuous recess 604 is formed in the artificial gingiva.

[0153] A claim may refer to any of the preceding claims, and any is understood to mean any one or more of the preceding claims.

[0154] The term obtaining as used in this specification may refer to physically acquiring for example medical images using a medical imaging device, but it may also refer for example to loading into a computer an image or a digital representation previously acquired.

[0155] It should be emphasized that the term comprises/comprising when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0156] The features of the method described above and in the following may be implemented in software and carried out on a data processing system or other processing means caused by the execution of computer-executable instructions. The instructions may be program code means loaded in a memory, such as a RAM, from a storage medium or from another computer via a computer network. Alternatively, the described features may be implemented by hardwired circuitry instead of software or in combination with software.

[0157] Although some embodiments have been described and shown in detail, the invention is not restricted to them, but may also be embodied in other ways within the scope of the subject matter defined in the following claims. In particular, it is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.