METHOD FOR MANUFACTURING A DENTAL PROSTHESIS AND SHELL MOULD CONFIGURED TO CARRY OUT THE METHOD

Abstract

Disclosed is a method for manufacturing a dental prosthesis, including a step of digitally designing a dental prosthesis model from a replica model of a patient's teeth, a step of generating a jaw portion model including the teeth replica model and the dental prosthesis model, a step of manufacturing a jaw portion including a positioning member based on the model of the jaw portion, and a step of positioning the jaw portion on a shell of a shell mold by the interaction of the positioning member of the jaw portion with a complementary positioning member arranged in the shell. Also disclosed is a shell mold used in such a method.

Claims

1. Method for manufacturing a dental prosthesis, said method comprising: digitally designing a dental prosthesis model to be made from a replica model of a patient's teeth; generating a jaw portion model including the teeth replica model and the model of the dental prosthesis assembled to said teeth replica model; digitally designing a positioning member model in the teeth replica model; manufacturing a jaw portion including a positioning member on the basis of the jaw portion model including a positioning member model; manufacturing a teeth replica including a positioning member on the basis of the teeth replica model including the positioning member model; positioning the jaw portion on a shell of a shell mold by interaction of the positioning member of the jaw portion with a complementary positioning member arranged in said shell; closing the shell mold; creating an imprint of the jaw portion by injection of a material into the shell mold; positioning at least one artificial tooth in the imprint of the jaw portion; positioning the teeth replica on the shell of the shell mold by interaction of the positioning member of the teeth replica with the complementary positioning member of the shell; positioning the teeth replica in the imprint in which the at least one artificial tooth is positioned; and casting a filling material in a residual volume defined by the imprint, the at least one artificial tooth and the teeth replica.

2. The method according to claim 1, wherein the positioning member interacts according to a sliding link with the complementary positioning member arranged on the shell.

3. The method according to claim 1, wherein the step of manufacturing the teeth replica is preceded by a step of parallelization of the teeth replica model, in which undercut zones are filled in digitally.

4. The method according to claim 1, wherein the step of positioning the teeth replica in the imprint is preceded by a step of positioning a stellite chassis on the teeth replica.

5. The method according to claim 1, further including a step of piercing a supply channel opening into the imprint.

6. The method according to claim 1, wherein the step of manufacturing the jaw portion and/or the teeth replica is carried out by additive manufacturing.

7. The method according to claim 6, wherein the step of manufacturing the jaw portion and/or the teeth replica is carried out according to a method comprising a succession of additions of material by jets on a printing support, in successive layers, the material being solidified by photopolymerization after each jet.

8. A shell mold for manufacturing a dental prosthesis, wherein a shell includes a complementary positioning member configured to interact with a positioning member of an insert to be positioned in the shell mold.

9. The shell mold according to claim 8, wherein the complementary positioning member is configured to form a sliding link with the positioning member of the insert.

10. The shell mold according to claim 8, wherein said complementary positioning member is configured to form a dovetail assembly with said positioning member.

11. The shell mold according to claim 10, wherein said complementary positioning member is configured to form a male portion of the dovetail assembly.

12. The shell mold according to claim 8, wherein said complementary positioning member includes a tab configured to interact with said positioning member.

13. The shell mold according to claim 8, wherein the complementary positioning member includes an axial stop.

14. The shell mold according to claim 12, wherein the complementary positioning member includes an axial stop, and wherein the axial stop is formed by a protruding surface, extending perpendicularly on either side of said tab, so that the complementary positioning member has the shape of a T.

15. The method according to claim 2, wherein the step of manufacturing the teeth replica is preceded by a step of parallelization of the teeth replica model, in which undercut zones are filled in digitally.

16. The method according to claim 15, wherein the step of positioning the teeth replica in the imprint is preceded by a step of positioning a stellite chassis on the teeth replica.

17. The method according to claim 16, further including a step of piercing a supply channel opening into the imprint.

18. The method according to claim 17, wherein the step of manufacturing the jaw portion and/or the teeth replica is carried out by additive manufacturing.

19. The method according to claim 18, wherein the step of manufacturing the jaw portion and/or the teeth replica is carried out according to a method comprising a succession of additions of material by jets on a printing support, in successive layers, the material being solidified by photopolymerization after each jet.

20. The shell mold according to claim 8, wherein: the complementary positioning member is configured to form a sliding link with the positioning member of the insert; said complementary positioning member is configured to form a dovetail assembly with said positioning member; said complementary positioning member is configured to form a male portion of the dovetail assembly; said complementary positioning member includes a tab configured to interact with said positioning member; the complementary positioning member includes an axial stop; and the axial stop is formed by a protruding surface, extending perpendicularly on either side of said tab, so that the complementary positioning member has the shape of a T.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0082] The invention, according to an exemplary embodiment, will be well understood and its advantages will be clearer upon reading the following detailed description, given for informational and in no way limiting purposes, in reference to the appended drawings in which:

[0083] FIG. 1 shows an example of a replica model of a patient's teeth according to an embodiment of the invention;

[0084] FIG. 2A shows a front high-angle view of the example of a replica model of a patient's teeth of FIG. 1, with a positioning member;

[0085] FIG. 2B shows a rear view, substantially low-angle, of the teeth replica model of FIG. 2A;

[0086] FIG. 3A shows an example of a model of a jaw portion, from a high angle, as obtained from the example of a teeth replica of FIGS. 2A and 2B, according to an embodiment of the invention;

[0087] FIG. 3B shows a rear view, substantially low-angle, of the example of a model of a jaw portion of FIG. 3A;

[0088] FIG. 4 shows a positioning of a jaw portion, carried out using the model of a jaw portion of FIGS. 3A and 3B, on a shell of a shell mould, according to an exemplary embodiment of the invention;

[0089] FIG. 5 illustrates, by a perspective view, a step of closing the shell mould with the jaw portion positioned on one of the shells, as illustrated in FIG. 4;

[0090] FIG. 6 shows an imprint of the jaw portion made in the shell mould and a step of forming a supply channel;

[0091] FIG. 7 shows a step of positioning an artificial tooth in the imprint of FIG. 6;

[0092] FIG. 8 shows a step of positioning a teeth replica, made from the teeth replica model of FIGS. 2A and 2B, on the shell of the shell mould of FIG. 4;

[0093] FIG. 9 illustrates by a perspective view a step of closing the shell mould with the teeth replica positioned on one of the shells as illustrated in FIG. 8;

[0094] FIG. 10 shows a step of casting a filling material inside the closed shell mould, including the teeth replica as shown in FIGS. 8 and 9;

[0095] FIG. 11 shows a dental prosthesis obtained according to an exemplary embodiment of the invention; and

[0096] FIG. 12 schematically shows a method for manufacturing a dental prosthesis according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION

[0097] The identical elements shown in the aforementioned drawings are identified by identical numerical references.

[0098] FIG. 1 shows a replica model of a patient's teeth 1.

[0099] Such a model is for example obtained via a step of taking a digital imprint (not illustrated) carried out on a model made of plaster via a table scanner or, preferably, directly via an intraoral scanner in the mouth of the patient.

[0100] The teeth replica model 1 thus corresponds to a digital representation of a portion of the jaw of a patient, in this case a lower jaw portion, for which a dental prosthesis must be made.

[0101] This teeth replica model 1 is generally stored in a file in the STL format and displayed using a piece of computer-aided design software.

[0102] The teeth replica model 1 includes for example an upper portion mainly forming a teeth portion, and a lower portion mainly forming a gums portion.

[0103] The teeth replica model 1 further includes a rear portion, or lingual portion, representing a concave inner face.

[0104] In the example illustrated, the teeth replica model 1 includes, in the upper portion, at least one missing tooth 3.

[0105] Moreover, in the example illustrated, the teeth replica model 1 includes at least one remaining tooth 5. The dental prosthesis to be made is in this case a partial dental prosthesis.

[0106] Of course, the present invention is not limited to this type of dental prosthesis and also applies to other types of prostheses, for example, to a complete dental prosthesis, that is to say for which the teeth replica model does not include any tooth 5.

[0107] As illustrated in FIGS. 2A and 2B, the teeth replica model 1 also includes a front portion, representing a convex outer face. The front portion is thus opposite to the rear portion, and the distance separating them forms the thickness of the teeth replica model 1.

[0108] The teeth replica model 1 further includes in the lower portion a lower surface 7.

[0109] This surface, once the teeth replica model 1 has been manufactured, is configured to position it in a stable manner on a support.

[0110] The lower surface 7 of the lower portion of the teeth replica model 1 defines for example a plane.

[0111] FIGS. 2A and 2B also show a positioning member model 8, arranged in the teeth replica model 1, at its lower portion. In particular, the positioning member model 8 is arranged starting from the lower surface 7 of the teeth replica model 1.

[0112] In the example shown, the positioning member model 8 includes a groove 8a. The groove 8a is configured to form a sliding link with a complementary member.

[0113] Indeed, the groove 8a extends according to a longitudinal axis between the rear portion and the front portion of the teeth replica model 1. The groove 8a has here a trapezoidal cross-section that allows, by interaction with a complementary member, only the movement according to a longitudinal axis of the groove 8a.

[0114] In the example shown in FIGS. 2A and 2B, the groove 8a is hollowed out starting from the lower surface 7 of the teeth replica model 1. The groove 8a extends parallel to the plane defined by the lower surface 7, over at least a portion of the thickness of the teeth replica model 1. In FIG. 2B for example, the groove 8a extends from the rear portion to the front portion of the teeth replica model 1, that is to say over the totality of the thickness of the teeth replica model 1. In other words, the groove 8a passes all the way through. In the present exemplary embodiment, the positioning member model 8 also includes a stop element or stop 8b configured to stop the movement in translation of the teeth replica model 1. According to an option of interest, the stop is formed by the front portion of the teeth replica model 1. In the present exemplary embodiment, the stop 8b includes a protrusion extending from the front portion of the teeth replica model 1. The protrusion of the stop 8b includes a flat surface, perpendicular to the longitudinal axis of the groove 8a.

[0115] FIG. 3A and FIG. 3B show a jaw portion model 2 comprising the teeth replica model 1 illustrated in FIGS. 2A and 2B and a dental prosthesis model 4, shown hatched, assembled by digital design to the teeth replica model 1.

[0116] The dental prosthesis model 4 is designed digitally on the basis of the teeth replica model 1. A profile and a shape of the prosthesis model are determined according to the teeth replica model 1 in order to best adapt to it. The profile of the dental prosthesis model 4 is also determined according to an axis of insertion, that is to say the trajectory for inserting the dental prosthesis model by simulation into the mouth of the patient. This axis of insertion is for example determined by the prosthetist or by the software.

[0117] Therefore, the dental prosthesis model 4 typically includes at least one tooth, and optionally a gum portion according to the teeth replica model 1, so as to form a jaw portion model 2 with corrected and complete teeth.

[0118] In the case of a partial dental prosthesis, the dental prosthesis model 4 can include a stellite chassis model (not t shown) configured to bear on at least one remaining tooth 5 and/or on a mucosa, in particular the gums, and/or to maintain together at least two separate parts of the dental prosthesis model.

[0119] It is understood that a lower portion of the jaw portion model 2 corresponds entirely to the lower portion of the teeth replica model 1. Indeed, only the hatched portion shown on the jaw portion model 2 differs from the teeth replica model 1. Thus, the jaw portion model 2 also includes the lower surface 7 at its lower portion. Consequently, the jaw portion model 2 also comprises the positioning member model 8, including here the groove 8a and the stop 8b, identical to the positioning member of the teeth replica model 1.

[0120] FIG. 4 illustrates a step of positioning of the jaw portion 20 on a shell 32 of a shell mould 30. The shell mould 30 includes here two shells: the shell 32 and a complementary shell 34 that is configured to interact with the shell 32 to close the shell mould 30.

[0121] For this, the shell 32 and the complementary shell 34 respectively include a notch 33a and a hook 33b. The hook 33b is configured to interact with the notch 33a to maintain the shell mould 30 closed. Of course, any other means for closing the shell mould 30 is possible, for example such as rubber bands.

[0122] The shell 32 has a bottom 35. The bottom 35 defines here a flat surface. The flat surface formed by the bottom 35 is intended to receive the jaw portion 20 on its lower surface 7 side.

[0123] According to the example shown, casting holes 38 are arranged in the complementary shell 34 in order to fill the shell mould 30 with a material with a view to the creation of an imprint of an insert.

[0124] The material for creating the imprint is a hydrocolloidal gel.

[0125] Such a shell mould 30 forms for example a dental flask.

[0126] FIG. 4 also shows an exemplary embodiment of a jaw portion 20, made from the jaw portion model 2 shown in FIGS. 3A and 3B.

[0127] The jaw portion 20 is for example made by additive manufacturing. For example, the jaw portion 20 is made from PA 12, or from photopolymerisable resin. In the exemplary embodiment described here, the jaw portion 20 is manufactured in a single piece.

[0128] The step of manufacturing the jaw portion 20 can further include, for example, a finishing substep. However, the parts made by additive manufacturing generally only require very few, or no, finishing touches; such a finishing step is therefore optional.

[0129] According to an aspect of interest of the invention, the shell 32 includes a complementary positioning member 36.

[0130] The complementary positioning member 36 of the shell 32 is configured to interact with a positioning member arranged in an insert, the overmoulding of which is to be carried out, in particular to form a sliding link. In the exemplary embodiment shown, the complementary positioning member 36 forms the male portion of a dovetail assembly.

[0131] In the present exemplary embodiment, the complementary positioning member 36 comprises an axial stop 36b to stop the movement in translation of the jaw portion 20 during the interaction of the complementary positioning member 36 with the positioning member 28. In general in the present description, an insert thus designates an object intended to be inserted into a mould to be overmoulded.

[0132] In the context of the present example, the insert in question is therefore the jaw portion 20.

[0133] As shown by FIG. 5, the jaw portion 20 includes a positioning member 28. The positioning member 28 is made from the positioning member model 8. In this case, the positioning member 28 includes here a groove 28a. According to the example shown, the positioning member 28 also includes a stop 28b formed at the front portion of the jaw portion 20.

[0134] The complementary positioning member 36 of the shell 32 is therefore configured to interact with the positioning member 28 of the jaw portion 20.

[0135] The complementary positioning member 36 is located on the bottom 35 of the shell 32. In particular, the complementary positioning member 36 protrudes from the bottom 35 of the shell 32.

[0136] According to the example shown, the complementary positioning member 36 comprises here a tab 36a, which has a shape complementary to that of the groove 28a. The tab 36a has for example a cross-section complementary to the cross-section of the groove 28a.

[0137] The tab 36a protrudes from the bottom 35 of the shell 32. The tab extends longitudinally according to the axis G shown in FIG. 5. The longitudinal axis G of the tab 36a is parallel to the flat surface formed by the bottom 35 of the shell 32 so that the movement of translation obtained during the interaction between the tab 36a and the groove 28a is carried out parallel to the flat surface formed by the bottom 35 of the shell 32.

[0138] Thus, during the interaction the between positioning member 28 and the complementary positioning member 36, the jaw portion 20 is moved parallel to the flat surface of the bottom 35 of the shell 32.

[0139] In the exemplary embodiment shown, the groove 28a forms the female portion of a dovetail assembly. The groove 28a includes for example a polygonal, and more precisely trapezoidal, cross-section. In the exemplary embodiment shown, the tab 36a forms the male portion of a dovetail assembly.

[0140] The dovetail assembly is used here to prevent the movement of the jaw portion 20 in an out-of-plane direction, for example orthogonal to the flat surface of the bottom 35 of the shell 32, and to maintain in position the jaw portion 20 for example during the separation of the complementary shell 34 and the shell 32 after a step of creating an imprint described more in details below.

[0141] Of course, the groove 28a of the positioning member 28 and/or the tab 36a of the complementary positioning member 36 according to the invention can have any other shape as long as they allow an interaction according to a sliding link. Thus, in an embodiment not shown, the positioning member 28 includes a tab protruding with respect to the lower surface of the jaw portion and the complementary positioning member includes a groove having a cross-section complementary to the tab of the positioning member. According to the example shown, the axial stop 36b is configured to interact with the positioning member 28 and more particularly with the front portion of the jaw portion 20, optionally with the stop 28b of the positioning member 28. This axial stop 36b also forms a reference for positioning of the jaw portion 20 on the shell 32.

[0142] The axial stop 36b is formed by a protruding surface, extending perpendicularly on either side of the tab 36a, so that the complementary positioning member 36 has the shape of a T. The axial stop 36b is for example located at an end of the tab 36a so as to be able to visualise the bearing in abutment with an insert, such as the jaw portion 20 and in this case with the stop 28b of the positioning member 28.

[0143] Of course, the axial stop 36b of the complementary positioning member 36 is not limited to the example shown and can be formed by any other means allowing to stop the movement in translation of an insert. In an embodiment not shown, the groove 28a formed by the positioning member 28 does not pass all the way through and is stopped by a longitudinal end of the tab 36a.

[0144] FIG. 6 illustrates the imprint 39 obtained after separation of the complementary shell 34 and the shell 32 carrying the jaw portion 20, that is to say when the shell mould 30 is open.

[0145] According to the example shown, the imprint 39 is formed from the material introduced by the casting holes 38. Thus, in the present example, the imprint 39 is integrally comprised in the complementary shell 34 of the shell mould 30.

[0146] As illustrated also in FIG. 6, the method includes a step of piercing a supply channel 37a, formed starting from at least one of the casting holes 38 of the complementary shell 34 and opening into the imprint 39. Such a supply channel 37a is for example made using a cannula 37b, for example a hollow cannula, inserted by one of the casting holes 38. In a non-limiting manner, the supply channel 37a preferably opens at a gums portion of the imprint 39.

[0147] Thus, such a method allows to create an imprint with a view to creating a custom dental prosthesis by moulding.

[0148] FIG. 7 illustrates a step of positioning at least one artificial tooth 42 in the imprint 39.

[0149] For example here, several artificial teeth 42 are positioned in the imprint 39. These teeth are intended to fill in the missing teeth, shown in the teeth replica model 1. Consequently, such artificial teeth 42 are positioned in the imprint 39, at the locations corresponding to the teeth previously designed by the software, as shown with hatching in FIGS. 3A and 3B for example.

[0150] FIG. 8 shows a step of positioning a teeth replica 10 on the shell 32 of the shell mould 30, in an analogous manner to the step of positioning the jaw portion 20 on the shell 32.

[0151] For example, the teeth replica 10 is made by additive manufacturing, on the basis of the teeth replica model 1, in a manner analogous to the creation of the jaw portion 20.

[0152] The teeth replica 10 consequently includes a positioning member 18, identical to the positioning member 28 of the jaw portion 20.

[0153] In this case, the positioning member 18 includes here a groove 18a. According to the example shown, the positioning member 18 also includes a stop 18b formed by the front face of the jaw portion 20.

[0154] The complementary positioning member 36 of the shell 32 is thus configured to interact with the positioning member 18 of the teeth replica 10. In this way, the teeth replica 10 is positioned on the shell 32 in a similar, or even identical, way to the jaw portion 20. In particular, the complementary positioning member 36 is configured to form a sliding link, and more particularly a dovetail assembly, with the positioning member 18.

[0155] The sliding link allows here a movement in translation of the teeth replica 10 according to the longitudinal axis G of the tab 36a, that is to say parallel to the flat surface of the bottom 35 of the shell 32.

[0156] The dovetail assembly is used to prevent the movement of the teeth replica 10 in a direction perpendicular to the flat surface of the bottom 35 of the shell 32, and to maintain in position the teeth replica 10 for example during the separation of the complementary shell 34 and of the shell 32 after a step of casting of a filling material described in more detail below.

[0157] FIG. 9 shows a step of positioning the teeth replica 10 in the imprint 39. For example, this step includes a step of closing the shell mould 30, by the interaction of the shell 32 and of the complementary shell 34, while the teeth replica 10 is positioned on the shell 32 and the imprint 39 is in the complementary shell 34.

[0158] The teeth replica 10 forms a sealed link with the imprint 39. This is explained in particular by the fact that the lower portion of the jaw portion 20 is identical to that of the teeth replica 10.

[0159] However, since their upper portion is different, the teeth replica 10 only partly fills the imprint 39, so as to form a residual volume in the imprint 39. This residual volume is both defined and delimited by the imprint 39, the artificial teeth 42 and the teeth replica 10.

[0160] In the case of a partial dental prosthesis, this volume is further defined by the stellite chassis 44 (FIG. 11), previously positioned on the teeth replica 10 before the closing of the shell mould 30.

[0161] FIG. 10 illustrates a casting step in which a filling material 46 is introduced via at least one of the casting holes 38 into the residual volume defined between at least the teeth replica 10 and the imprint 39. In this case, in the example shown, the filling material 46 is introduced via the supply channel 37a.

[0162] During this step, the filling material 46 comes in contact with at least a portion of the artificial teeth 42 to bond thereto, for example, by overmoulding. The same applies for the stellite chassis 44 in the case of a partial prosthesis.

[0163] The filling material 46 can be injected under pressure or by natural gravitational filling, so as to best adjust to the walls of the residual volume. The filling material 46 can comprise any type of material known for the manufacturing of a dental prosthesis, such as an acrylic resin for example.

[0164] The method further includes a step of separating the teeth replica 10 and the imprint 39, or even for example of opening the shell mould 30, then a step of extracting (not illustrated) an unsurfaced blank configured to form the dental prosthesis.

[0165] The method also includes for example a finishing step which can include a step of eliminating an injection sprue corresponding to the moulding of the supply channel, and/or a finishing step involving for example a polishing and/or a deburring and/or a buffing of the unsurfaced blank.

[0166] FIG. 11 illustrates an example of a prosthesis 40 obtained after this method according to an exemplary embodiment. According to the example shown, the prosthesis 40 includes the artificial teeth 42 and the stellite chassis 44 which are bonded to the solidified filling material 46 forming a gum.

[0167] In the present exemplary embodiment, the dental prosthesis 40 is a partial dental prosthesis. Indeed, the stellite chassis 44 connects two portions each including at least one artificial tooth 42 bonded to the solidified filling material 46.

[0168] Adjustment steps can be carried out by positioning the dental prosthesis 40 on the teeth replica 10, before being inserted into the mouth of the patient.

[0169] FIG. 12 schematically illustrates an exemplary embodiment of a method for manufacturing a dental prosthesis according to the invention.

[0170] According to this example, the method includes: [0171] a step S1 of digitally designing the dental prosthesis model to be made on the basis of the replica model of a patient's teeth 1, as illustrated in FIG. 1; [0172] a step S2, in which the positioning member model 8 is digitally designed in the teeth replica model 1; [0173] a step S3 of parallelising the teeth replica model 1, in which undercut zones are filled in digitally; [0174] a step S4 of generating the jaw portion model 2, as illustrated in FIGS. 3A and 3B, including the teeth replica model 1 and the model of the dental prosthesis assembled to said teeth replica model 1; [0175] a step S5 involves the manufacturing of the jaw portion 20 on the basis of the jaw portion model 2 including a positioning member 28, for example by additive manufacturing; [0176] a step S6 involves the manufacturing of a teeth replica 10 on the basis of the teeth replica model 1 including a positioning member 18, for example by additive manufacturing; [0177] a step S7, as illustrated in FIG. 4, of positioning the jaw portion 20 on a shell 32 of a shell mould 30 by interaction of the positioning member 28 of the jaw portion 20 with the complementary positioning member 36 arranged in said shell 32; [0178] once the jaw portion 20 is positioned on the shell 32, the shell mould 30 is closed during a step S8, illustrated by FIG. 5; [0179] a step S9 of creating an imprint 39 of the jaw portion is thus carried out 20 by injection of a material into the shell mould 30. This step gives rise to the formation of an imprint 39 of the jaw portion; [0180] a step S10 of piercing a supply channel opening into the imprint 39; [0181] a step S11 of positioning at least one artificial tooth in the imprint of the jaw portion 20, as illustrated in FIG. 7; [0182] a step S12, shown for example by FIG. 8, of positioning the teeth replica 10 on the shell 32 of the shell mould 30 by interaction of the positioning member 18 of the teeth replica 10 with the complementary positioning member 36 of the shell 32; [0183] a step S13 of positioning a stellite chassis 44 on the teeth replica 10, when a partial dental prosthesis is involved. [0184] a step S14, shown for example by FIG. 9, of positioning the teeth replica 10 in the imprint 39 in which at least one artificial tooth 42 is positioned; [0185] a step S15, illustrated for example in FIG. 10, of casting a filling material 46 in a residual volume defined by the imprint 39, the at least one artificial tooth 42 and the teeth replica 10.