INTEGRATED SUPPORT DEVICE FOR PROVIDING TEMPORARY PRIMARY STABILITY TO DENTAL IMPLANTS AND PROSTHESIS, AND RELATED METHODS

Abstract

Integrated support devices for providing temporary primary stability to a dental prosthesis implant, each individually designed and manufactured for a specific pre-identify patient are also provided. An integrated support device can include a prosthesis interface member configured to connect to an abutment or reduced sized portion of a dental prosthesis/implant. The integrated support device also includes one or more bonding wings for connecting to the adjacent healthy teeth.

Claims

1. A system for providing support to a dental prosthesis positioned in a specific jawbone cavity of a specific pre-identified patient, the dental prosthesis comprising an occlusal-facing custom-made dental implant component connected to or integral with a dental implant, the system comprising: a first virtual model modeling a natural crown of a tooth number associated with the specific jawbone cavity or an artificial crown, temporary or permanent, configured to be positioned atop of the occlusal-facing custom-made dental implant component to thereby define a crown of the tooth number associated with the specific jawbone cavity, the first virtual model including at least a first virtual shape of an occlusal-extending spatial surface of the crown of the tooth number associated with the specific jawbone cavity; a second virtual model modeling one or more adjacent functional teeth, crowns, or prosthetic structures of a first jaw of the specific pre-identified patient in which the specific jawbone cavity is present and adjacent to the specific jawbone cavity to thereby define an adjacent dental structure, the second virtual model including at least one or more second virtual shapes of one or more occlusal-extending spatial surfaces of one or more crown portions of the adjacent dental structure; a third virtual model modeling a first virtual spatial geometrical relation between the first virtual model and the second virtual model correlating to a spatial geometrical relation between a portion of the specific jawbone cavity and a portion of the adjacent dental structure; and design data modeling a temporary occlusal-facing dental device, the design data comprising: a virtual device interface member modeling a device interface member of the temporary occlusal-facing dental device, the virtual device interface member includes a virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess, modeling an occlusal-extending asymmetrical custom-shaped spatial recess extending into a body of the device interface member, the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess is an inverse virtual shape correlated to a corresponding portion of the first virtual shape; and one or more virtual bonding wings modeling one or more bonding wings connected to or integral with the device interface member, the one or more virtual bonding wings have one or more virtual occlusal-extending custom-designed spatial bonding surfaces modeling one or more occlusal-extending custom-shaped spatial bonding surfaces, the one or more virtual occlusal-extending custom-designed spatial bonding surfaces are one or more inverse virtual shapes correlated to one or more corresponding portions of the one or more second virtual shapes; and a second virtual spatial geometrical relation between the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess and the one or more virtual occlusal-extending custom-designed spatial bonding surfaces correlating to the first virtual spatial geometrical relation.

2. The system as defined in claim 1, the system further comprising: a fourth virtual model modeling one or more functional opponent crowns of one or more opponent functional teeth or opponent prosthetic structures in a jaw of the specific pre-identified patient opponent to the first jaw of and adjacent the specific jawbone cavity to thereby define an opponent occlusal structure, the fourth virtual model including at least one or more third virtual shapes of one or more occlusal-extending spatial surfaces of the opponent occlusal structure, and a third virtual spatial geometrical relation between the one or more third virtual shapes and the one or more second virtual shapes correlating to a spatial geometrical relation between a portion of the adjacent dental structure and a portion of the opponent occlusal structure in an occluded upper to lower jaw relationship of the specific pre-identified patient; and one or more virtual occlusal-facing shapes of the virtual device interface member and of the one or more virtual bonding wings are custom-designed not to virtually intrude into the one or more third virtual shapes.

3. The system as defined in claim 1, the system further comprising: a fifth virtual model modeling the dental prosthesis and a user desired position and inclination of the dental prosthesis in spatial relation to at least the adjacent dental structure of the specific pre-identified patient, the fifth virtual model including at least a fourth virtual shape of a virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial rising modeling an occlusal-extending asymmetrical custom-shaped spatial rising of the occlusal-facing custom-made dental implant component, and a fourth virtual spatial geometrical relation between the fourth virtual shape and the one or more second virtual shapes correlating to a user desired spatial geometrical relation between at least a portion of the dental prosthesis and a portion of the adjacent dental structure of the specific pre-identified patient; and the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess included in the design data modeling the temporary occlusal-facing dental device is an inverse virtual shape correlated to a corresponding portion of the fourth virtual shape, and the fourth virtual spatial geometrical relation correlates to the first virtual spatial geometrical relation.

4. The system as defined in claim 1, the system further comprising: the temporary occlusal-facing dental device, the temporary occlusal-facing dental device shaped responsive to the design data prior to an insertion of the dental prosthesis into the specific jawbone cavity of the specific pre-identified patient and prior to a positioning of the temporary occlusal-facing dental device on the adjacent dental structure of the specific pre-identified patient; the temporary occlusal-facing dental device comprising: the device interface member configured to be positioned atop of and to surround substantial portions of an occlusal-extending asymmetrical custom-shaped spatial rising of the occlusal-facing custom-made dental implant component, the device interface member includes the occlusal-extending asymmetrical custom-shaped spatial recess extending into a body of the device interface member, the occlusal-extending asymmetrical custom-shaped spatial recess is an inverse shape correlated to a corresponding portion of the first virtual shape, and the one or more bonding wings connected to or integral with the device interface member and configured to bond to one or more corresponding portions of the adjacent dental structure when operably positioned thereon to at least substantially rigidly fixate the device interface member to support the dental prosthesis, so that the dental prosthesis is maintained at a user desired position and inclination of the dental prosthesis in spatial relation to at least the adjacent dental structure; the one or more occlusal-extending custom-shaped spatial bonding surfaces are correlated to corresponding portions of the one or more second virtual shapes; and the spatial geometrical relation between the occlusal-extending asymmetrical custom-shaped spatial recess and the one or more occlusal-extending custom-shaped spatial bonding surfaces correlate to the first virtual spatial geometrical relation.

5. The system as defined in claim 2, the system further comprising: the temporary occlusal-facing dental device, the temporary occlusal-facing dental device shaped responsive to the design data prior to an insertion of the dental prosthesis into the specific jawbone cavity of the specific pre-identified patient and prior to a positioning of the temporary occlusal-facing dental device on the adjacent dental structure of the specific pre-identified patient; the temporary occlusal-facing dental device comprising: the device interface member configured to be positioned atop of and to surround substantial portions of the occlusal-extending outward-facing asymmetrical custom-shaped spatial rising of the dental implant component, the device interface member includes the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member, the occlusal-extending asymmetrical custom-shaped spatial recess is an inverse shape correlated to a corresponding portion of the first virtual shape, and the one or more bonding wings connected to or integral with the device interface member and configured to bond to one or more corresponding portions of the adjacent dental structure when operably positioned thereon to at least substantially rigidly fixate the device interface member to support the dental prosthesis, so that the dental prosthesis is maintained at a user desired position and inclination of the dental prosthesis in spatial relation to at least the adjacent dental structure; the one or more occlusal-extending custom-shaped spatial bonding surfaces are correlated to corresponding portions of the one or more second virtual shapes; the spatial geometrical relation between the occlusal-extending asymmetrical custom-shaped spatial recess and the one or more occlusal-extending custom-shaped spatial bonding surfaces correlate to the first virtual spatial geometrical relation; and one or more occlusal-facing custom-shaped surfaces of the device interface member are not in contact with the opponent occlusal structure when the temporary occlusal-facing dental device is operably positioned on the adjacent dental structure and the specific pre-identified patient attempts to approach an occluded upper to lower jaw relationship.

6. The system as defined in claim 3, the system further comprising: the temporary occlusal-facing dental device, the temporary occlusal-facing dental device shaped responsive to the design data prior to an insertion of the dental prosthesis into the specific jawbone cavity of the specific pre-identified patient and prior to a positioning of the temporary occlusal-facing dental device on the adjacent dental structure of the specific pre-identified patient; the temporary occlusal-facing dental device comprising: the device interface member configured to be positioned atop of and to surround substantial portions of the occlusal-extending outward-facing asymmetrical custom-shaped spatial rising of the dental implant component, the device interface member includes the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member, the occlusal-extending asymmetrical custom-shaped spatial recess is an inverse shape correlated to a corresponding portion of the fourth virtual shape, and the one or more bonding wings connected to or integral with the device interface member and configured to bond to one or more corresponding portions of the adjacent dental structure when operably positioned thereon to at least substantially rigidly fixate the device interface member to support the dental prosthesis, so that the dental prosthesis is maintained at a user desired position and inclination of the dental prosthesis in spatial relation to at least the adjacent dental structure; the one or more occlusal-extending custom-shaped spatial bonding surfaces are correlated to corresponding portions of the one or more second virtual shapes; and the spatial geometrical relation between the occlusal-extending asymmetrical custom-shaped spatial recess and the one or more occlusal-extending custom-shaped spatial bonding surfaces correlate to the fourth virtual spatial geometrical relation.

7. The system as defined in claim 1, wherein the occlusal-facing custom-made dental implant component is a partially custom-shaped abutment connected to the dental implant.

8. The system as defined in claim 1, wherein the occlusal-facing custom-made dental implant component and the dental implant are monolithically formed as one part.

9. The system as defined in claim 1, wherein the design data modeling the temporary occlusal-facing dental device comprises a virtual shape modeling a temporary crown.

10. The system as defined in claim 4, wherein the one or more bonding wings are a portion of a splint connected to the device interface member.

11. The system as defined in claim 10, wherein the splint is configured to provide elasticity.

12. The system as defined in claim 4, wherein the device interface member and the one or more bonding wings are monolithically formed as one part, and wherein the device interface member entailing the one or more bonding wings, and the one or more bonding wings arising outwardly from a surface of the device interface member toward one or more corresponding adjacent crowns.

13. The system as defined in claim 4, wherein the temporary occlusal-facing dental device is configured to provide elasticity.

14. The system as defined in claim 1, wherein the dental implant is configured for osseointegration in the specific jawbone cavity of a specific pre-identified patient.

15. The system as defined in claim 1, wherein the dental implant is configured for integration in the specific jawbone cavity of a specific pre-identified patient through a regeneration of a periodontal membrane.

16. The system as defined in claim 1, wherein the dental implant includes a custom-shaped root portion correlating to a shape of the specific jawbone cavity.

17. The system as defined in claim 4, wherein at least one of the one or more bonding wings is configured to be bonded to more than one functional adjacent crowns.

18. The system as defined in claim 6, wherein an at least semirigid connection is formed between the device interface member and the occlusal-extending asymmetrical custom-shaped spatial rising of the occlusal-facing custom-made dental implant component to at least semirigidly fixate the device interface member to the occlusal-extending asymmetrical custom-shaped spatial rising to stabilize and provide primary stability to the dental prosthesis, the device interface member and the dental prosthesis forming a form-lock fit when placed together.

19. The system as defined in claim 1, wherein the first virtual shape shows a substantial virtual asymmetric apical-facing indent extending into a virtual body of the crown of the tooth number associated with the specific jawbone cavity, and wherein the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess shows an inverse virtual shape correlated to a corresponding portion of the substantial virtual asymmetric apical-facing indent.

20. The system as defined in claim 4, wherein the body of the device interface member of the temporary occlusal-facing dental device comprises a custom-shaped crown portion, and wherein an outward facing outline of a cross-section of the crown portion correlates to an inward facing outline of a corresponding cross-section of the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member.

21. The system as defined in claim 1, wherein the one or more virtual bonding wings are designed to be sufficiently small so that the one or more bonding wings of the temporary occlusal-facing dental device shaped responsive to the corresponding one or more virtual bonding wings included in the design data are dimensioned to be sufficiently small as to not extend atop a portion of an incisal surface of a corresponding adjacent functional tooth that is normally aligned to contact a surface of a corresponding opposite-facing functional tooth when the respective tooth is an anterior tooth, and so as to not extend atop a portion of an occlusal surface of the corresponding adjacent functional tooth that is normally aligned to contact an occlusal surface of a corresponding opposite-facing functional tooth when the respective tooth is a posterior tooth.

22. The system as defined in claim 1, the system further comprising: first imaging data including a three-dimensional representation of at least a portion of the natural crown of the tooth number associated with the specific jawbone cavity, and wherein the first virtual model is responsive to the first imaging data.

23. The system as defined in claim 22, the system further comprising: second imaging data including a three-dimensional representation of at least a portion of the adjacent dental structure, and wherein the second virtual model is responsive to the second imaging data.

24. The system as defined in claim 23, the system further comprising: third imaging data including a three-dimensional representation of at least a portion of the opponent occlusal structure, and wherein the fourth virtual model is responsive to the third imaging data.

25. The system as defined in claim 3, the system further comprising: in-vivo imaging data including a three-dimensional representation of at least a portion of the spatial relation of the specific jawbone cavity and the adjacent dental structure, and wherein the fifth virtual model is responsive to the in-vivo imaging data.

26. A method of designing and manufacturing a temporary occlusal-facing dental device to support a dental prosthesis to replace a non-functional tooth of a specific pre-identified patient when the dental prosthesis is positioned within and being integrated into a specific jawbone cavity of the specific pre-identified patient, the dental prosthesis comprising an occlusal-facing custom-made dental implant component connected to or integral with a dental implant, the method including the steps of: receiving first shape data including at least one of the following: a first virtual shape modeling at least a portion of an occlusal-extending spatial surface of a crown of a tooth number associated with the specific jawbone cavity of the specific pre-identified patient, and a second virtual shape modeling at least a portion of an occlusal-extending asymmetrical artificially-shaped custom-designed custom-made spatial rising of the occlusal-facing custom-made dental implant component, the crown of the tooth number associated with the specific jawbone cavity includes a natural crown of a tooth number associated with the specific jawbone cavity or an artificial crown, temporary or permanent, configured to be positioned atop of the occlusal-facing custom-made dental implant component; receiving second shape data including one or more virtual shapes of one or more occlusal-extending spatial surfaces of one or more crown portions of an adjacent dental structure of the specific pre-identified patient, the adjacent dental structure includes one or more adjacent functional teeth, crowns, or prosthetic structures of a first jaw of the specific pre-identified patient in which the specific jawbone cavity is present, adjacent to the specific jawbone cavity; receiving first spatial data representing a first spatial geometrical relation between the first shape data and the second shape data; deriving third shape data from the first shape data, the third shape data include a virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess; deriving fourth shape data from the second shape data, the fourth shape data include one or more virtual occlusal-extending custom-designed spatial bonding surfaces; forming device design data modeling a temporary occlusal-facing dental device responsive to the first spatial geometrical relation, the third shape data, and the fourth shape data, the design data comprising: a virtual device interface member modeling a device interface member of the temporary occlusal-facing dental device, the virtual device interface member includes the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess as determined by the third shape data, modeling an occlusal-extending asymmetrical custom-shaped spatial recess extending into a body of the device interface member; and one or more virtual bonding wings modeling one or more bonding wings connected to or integral with the device interface member, the one or more virtual bonding wings include the one or more virtual occlusal-extending custom-designed spatial bonding surfaces as determined in the fourth shape data modeling one or more occlusal-extending custom-shaped spatial bonding surfaces, the one or more virtual occlusal-extending custom-designed spatial bonding surfaces are one or more inverse virtual shapes correlated to one or more corresponding portions of the second shape data; and a virtual spatial geometrical relation between the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess and the one or more virtual occlusal-extending custom-designed spatial bonding surfaces correlating to the first spatial geometrical relation.

27. The method as defined in claim 26, wherein the first shape data includes the first virtual shape, and wherein the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess is an inverse virtual shape correlated to a corresponding portion of the first virtual shape.

28. The method as defined in claim 26, wherein the first shape data includes the second virtual shape, and wherein the virtual occlusal-extending asymmetrical artificially-shaped custom-designed spatial recess is an inverse virtual shape correlated to a corresponding portion of the second virtual shape.

29. The method as defined in claim 26, the method further including the steps of: receiving in-vivo volumetric 3D imaging data taken from dental structures of and the dental structure adjacent to the specific jawbone cavity of the specific pre-identified patient, the in-vivo volumetric 3D imaging data representing a clinical situation prior to a removal of the non-functional tooth to be replaced by the dental prosthesis, the in-vivo volumetric 3D imaging data including a three-dimensional representation of at least a portion of the spatial relation of the specific jawbone cavity and the adjacent dental structure; and deriving the first spatial data from the in-vivo volumetric 3D imaging data.

30. The method as defined in claim 26, the method further including the steps of: receiving in-vivo surface 3D imaging data taken, directly or indirectly, from dental structures adjacent the specific jawbone cavity of the specific pre-identified patient, the in-vivo surface 3D imaging data representing a clinical situation prior to a removal of the non-functional tooth to be replaced by the dental prosthesis, the natural crown of a tooth number associated with the specific jawbone cavity is a natural crown of the non-functional tooth to be replaced by the dental prosthesis, the in-vivo surface 3D imaging data including a three-dimensional representation of at least a portion of the spatial relation of the natural crown and the adjacent dental structure; and deriving the first spatial data from the in-vivo surface 3D imaging data.

31. The method as defined in claim 27, where in the method steps of deriving third shape data from the first shape data employs method steps virtually reducing dimensions of the first virtual shape.

32. The method as defined in claim 26, the method further including the steps of: shaping the temporary occlusal-facing dental device responsive to the device design data; the temporary occlusal-facing dental device comprising: the device interface member configured to be positioned atop of and to surround substantial portions of the occlusal-extending outward-facing asymmetrical custom-shaped spatial rising of the dental implant component, the device interface member includes the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member, the occlusal-extending asymmetrical custom-shaped spatial recess is an inverse shape correlated to a corresponding portion of the first virtual shape, and the one or more bonding wings connected to or integral with the device interface member and configured to bond to one or more corresponding portions of the adjacent dental structure when operably positioned thereon to at least substantially rigidly fixate the device interface member to support the dental prosthesis, so that the dental prosthesis is maintained at a user desired position and inclination of the dental prosthesis in spatial relation to at least the adjacent dental structure; and the one or more occlusal-extending custom-shaped spatial bonding surfaces are one or more inverse shapes correlated to one or more corresponding portions of second shape data; and the spatial geometrical relation between the occlusal-extending asymmetrical custom-shaped spatial recess and the one or more occlusal-extending custom-shaped spatial bonding surfaces correlate to the first virtual spatial geometrical relation.

33. The method as defined in claim 32, the method further including the step of: configuring the one or more occlusal-extending custom-shaped spatial bonding surfaces to bond to one or more corresponding surface portions of the adjacent dental structure when operably positioned thereon to at least substantially rigidly fixate the temporary occlusal-facing dental device to the adjacent dental structure of the specific pre-identified patient.

34. The method as defined in claim 32, the method further including the step of: configuring the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member to surround substantial portions of the occlusal-extending asymmetrical artificially-shaped custom-designed custom-made spatial rising of the occlusal-facing custom-made dental implant component connected or integral with the dental implant when operably positioned thereon to at least protect the dental prosthesis against movement induced by mastication forces to thereby maintain the dental prosthesis in a user desired position and inclination.

35. The method as defined in claim 32, the method further including the step of: configuring the occlusal-extending asymmetrical custom-shaped spatial recess extending into the body of the device interface member to form a form-locking fit with and to engage and land atop and surround substantial portions of the occlusal-extending asymmetrical artificially-shaped custom-designed custom-made spatial rising of the occlusal-facing custom-made dental implant component connected or integral with the dental implant when operably positioned thereon to at least substantially rigidly fixate the temporary occlusal-facing dental device to the dental implant component connected or integral with the dental implant to thereby stabilize the dental implant in a user desired position and inclination and provide temporary primary stability to the dental implant when the dental implant is positioned within and being integrated into the specific jawbone cavity.

36. A method as defined in claim 32, wherein at least one method step of designing the temporary occlusal-facing dental device employs computer-aided design (CAD) processes.

37. A method as defined in claim 32, wherein at least one method step of manufacturing the temporary occlusal-facing dental device employs computer-aided manufacturing (CAM) processes.

38. A method as defined in claim 32, wherein at least one method step of shaping the temporary occlusal-facing dental device employs computerized numerical control (CNC) machinery.

39. A method as defined in claim 38, wherein at least one method step of shaping the temporary occlusal-facing dental device employs subtractive machining technologies.

40. A method as defined in claim 39, wherein at least one method step of shaping the temporary occlusal-facing dental device employs grinding, turning or milling technologies.

41. A method as defined in claim 38, wherein at least one method step of shaping the temporary occlusal-facing dental device employs additive or generative rapid prototyping (3D printing) technologies.

42. A method as defined in claim 41, wherein at least one method step of shaping the temporary occlusal-facing dental device utilizes additive or generative rapid prototyping materials (3D printing materials).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] So that the manner in which the features and advantages of the invention, as well as others which will become apparent, may be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it may include other effective embodiments as well.

[0062] FIG. 1 illustrates a procedure of replacing a human tooth with a prosthesis in accordance with an aspect of the invention.

[0063] FIG. 2 is a detailed cross-sectional view of a natural tooth.

[0064] FIG. 3 illustrates the process steps of intra-orally acquiring three-dimensional data of a human tooth, fabricating an artificial copy, extracting the natural tooth and replacing it with the artificial copy according to an embodiment of the invention.

[0065] FIG. 4 illustrates an artificial tooth (an dental prosthesis) inserted into the extraction socket and, after a healing period, fully integrated into the bone.

[0066] FIG. 5 illustrates an artificial tooth being embedded in the socket of the natural tooth.

[0067] FIG. 6 illustrates a natural tooth having strongly crooked roots and the artificial substitute, wherein the shape of the substitute has been altered in order to allow for simplified insertion into the natural socket.

[0068] FIG. 7 illustrates a natural tooth suffering from partial root loss due to root resorption or a surgical procedure and an artificial substitute, the shape of the artificial tooth being optimized for better adaption to the natural socket.

[0069] FIG. 8 illustrates a tooth socket after extraction. Due to root resorption, the size of the socket has been reduced over time. In order to enhance anchoring, the artificial replacement will have a root portion of greater size. Therefore, the socket is surgically enlarged.

[0070] FIG. 9 illustrates an artificial tooth, the portion representing the root being slightly reduced in size compared to the natural tooth.

[0071] FIG. 10 is a view of a bridge according to an embodiment of the present invention.

[0072] FIG. 11 is a view of a segmented artificial tooth, the segment representing the root and the segment representing the crown having an interlocking connection.

[0073] FIG. 12 illustrates a single-tooth prosthesis for osseointegration showing a custom shaped torus as a barrier against tissue growth.

[0074] FIG. 13 illustrates a single-tooth prosthesis showing a labyrinth-sealing feature between a single-tooth prosthesis and the gingiva as barrier against bacteria infiltration.

[0075] FIG. 14 illustrates a single-tooth prosthesis showing a build-up of a crown portion of translucent ceramic layers.

[0076] FIG. 15 illustrates a single-tooth prosthesis showing a root portion having drug releasing surface.

[0077] FIG. 16 illustrates an iterative method for processing previously acquired data for the fabrication of the mentioned prosthesis.

[0078] FIGS. 17A-17C illustrate a prior-art dental implant.

[0079] FIG. 18 illustrates a natural tooth.

[0080] FIG. 19 illustrates a dental implant prosthesis with a custom-shaped joint between an implant body (having a root portion and an transgingival portion) and a crown.

[0081] FIGS. 20A and 20B illustrate a proximal lateral view of a dental prosthesis and a cross-sectional lateral view of the dental implant body, respectively.

[0082] FIG. 21 illustrates a dental implant prosthesis with a custom-shaped joint between an implant body (having a root portion and an transgingival portion) and a crown.

[0083] FIG. 22 illustrates numerically combining surface image data with an x-ray image data with the help of a computer to form a three-dimensional virtual model.

[0084] FIG. 23 illustrates the division or separation of parts of a virtual model.

[0085] FIG. 24 illustrates copying of portions of the divided virtual model.

[0086] FIG. 25 illustrates the combining of virtual models to form a virtual crown portion.

[0087] FIG. 26 illustrates the combining of virtual models to form a virtual dental implant body.

[0088] FIG. 27 illustrates the attachment of a crown portion of a dental implant to a dental implant body to form the dental implant.

[0089] FIG. 28 illustrates a compound one-piece prosthesis with a first joint between an implant body and a transgingival cap and a second joint between the transgingival cap and a crown.

[0090] FIG. 29 illustrates an exploded view of a dental prosthesis consisting of a crown, a trans-gingival portion, an implant body, and a splint.

[0091] FIG. 30 illustrates labial view of a dental implant prosthesis.

[0092] FIG. 31 illustrates cross-sectional labial view of a dental implant prosthesis.

[0093] FIG. 32 illustrates a top view and a cross-sectional transversal view of a dental implant body.

[0094] FIG. 33 illustrates the division or separation of parts of a virtual model.

[0095] FIG. 34 illustrates copying of portions of the divided virtual model.

[0096] FIG. 35 illustrates the combining of virtual models to form a virtual dental implant body portion.

[0097] FIG. 36 illustrates the combining of virtual models to form a virtual transgingival cap portion.

[0098] FIG. 37 illustrates the combining of virtual models to form a virtual crown portion.

[0099] FIG. 38 illustrates the attachment of a transgingival cap portion of a dental implant to a dental implant body and attachment of a crown portion to the transgingival cap portion to form the dental implant.

[0100] FIG. 39 illustrates a completed three-piece dental implant.

[0101] FIG. 40 is a partially cross-sectional view of an exemplary compound one-piece prosthesis showing a first joint between an implant body and a transgingival interlock abutment and a second joint between the transgingival interlock abutment and a dental prosthesis component or crown according to an embodiment of the present invention.

[0102] FIG. 41 is a perspective view of the exemplary compound one-piece prosthesis of

[0103] FIG. 40 according to an embodiment of the present invention.

[0104] FIG. 42 is a perspective view of an implant body according to an embodiment of the present invention.

[0105] FIG. 43 is a perspective view of a transgingival interlock abutment according to an embodiment of the present invention.

[0106] FIG. 44 is a perspective view illustrating the transgingival interlock abutment shown in FIG. 43 landed within the implant body shown in FIG. 42 according to an embodiment of the present invention.

[0107] FIG. 45 is an exploded view of the exemplary prosthesis shown in FIG. 41 according to an embodiment of the present invention.

[0108] FIG. 46 is an exploded view of portions of the exemplary prosthesis shown in FIG. 41 supported by an integrated support device according to an embodiment of the present invention.

[0109] FIG. 47 is a part perspective view illustrating division of a virtual model into separate parts according to an embodiment of the present invention.

[0110] FIG. 48 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0111] FIG. 49 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0112] FIG. 50 is a sectional view illustrating copying of part of a virtual model according to an embodiment of the present invention.

[0113] FIG. 51 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0114] FIG. 52 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0115] FIG. 53 is a sectional view illustrating the combining of virtual models to form a virtual crown portion according to an embodiment of the present invention.

[0116] FIG. 54 is a sectional view illustrating the combining of virtual models to form a virtual trans-gingival interlock abutment portion according to an embodiment of the present invention.

[0117] FIG. 55 is a sectional view illustrating the combining of virtual models to form a virtual dental implant body portion according to an embodiment of the present invention.

[0118] FIG. 56 is a sectional view illustrating the combining of virtual models to form a virtual dental prosthesis according to an embodiment of the present invention.

[0119] FIG. 57 is an environmental view illustrating a prosthesis with a crown portion body forming one part with bonding wings according to an embodiment of the present invention.

[0120] FIG. 58 is a sectional (cut away) view of the prosthesis with a crown portion body forming one part with the bonding wings illustrated in FIG. 57 according to an embodiment of the present invention.

[0121] FIG. 59 is a perspective view of an integrated support device according to an embodiment of the present invention.

[0122] FIG. 60 is a perspective view of an integrated support device according to an embodiment of the present invention.

[0123] FIG. 61 is an exploded view of the integrated support device shown in FIG. 59 connected to portions of the exemplary prosthesis shown in FIG. 44 according to an embodiment of the present invention.

[0124] FIG. 62 is an exploded view of the integrated support device shown in FIG. 59 connected to portions of an exemplary prosthesis according to an embodiment of the present invention.

[0125] FIG. 63 is a perspective view of the integrated support device shown in FIG. 59 connected to portions of the exemplary prosthesis shown in FIG. 44 according to an embodiment of the present invention.

[0126] FIG. 64 is a perspective view of the exemplary prosthesis shown in FIG. 62 according to an embodiment of the present invention.

[0127] FIG. 65 is a perspective environmental view of an integrated support device connected to adjacent functional teeth according to an embodiment of the present invention.

[0128] FIG. 66 is a perspective view of an integrated support device according to an embodiment of the present invention.

[0129] FIG. 67 is a perspective view of an occlusal portion of the crown surfaces of natural opposing teeth.

[0130] FIG. 68 is a perspective lingual view of an integrated support structure together with opposing crown portions illustrating the comparative shape of the bonding wings and illustrating that although covering the lingual and even an occlusally reaching portion from the adjacent teeth, the bonding wings can avoid an occlusal biting interference with opposing teeth according to an embodiment of the present invention.

[0131] FIG. 69 is a perspective lingual view illustrating the integrated support structure of FIG. 68 at a different vertically angled lingual view according to an embodiment of the present invention.

[0132] FIG. 70 is a perspective buccal view illustrating the integrated support structure according to an embodiment of the present invention.

[0133] FIG. 71 is a perspective lingual view illustrating an integrated support structure adapted for application on natural anterior teeth according to an embodiment of the present invention.

[0134] FIG. 72 is a perspective environmental view of an integrated support device connected to natural adjacent functional teeth according to an embodiment of the present invention.

[0135] FIG. 73 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0136] FIG. 74 is a sectional view illustrating copying and restructuring of parts of a virtual model according to an embodiment of the present invention.

[0137] FIG. 75 is a sectional view illustrating the combining of virtual models to form a virtual prosthesis interface member model according to an embodiment of the present invention.

[0138] FIG. 76 is a sectional view illustrating the combining of the virtual prosthesis interface member with a skin model of a set of bonding wings according to an embodiment of the present invention.

[0139] FIG. 77 is a sectional view illustrating the combining of the resultant model shown in FIG. 76 with a copy of the skin model to form the bonding wings and to complete the model construction of an integrated support device according to an embodiment of the present invention.

[0140] FIGS. 78A-78B each illustrate a single-tooth prosthesis and a custom-made splint for positioning and fixation of such to the adjacent dental structure, according to an embodiment of the present invention.

[0141] FIG. 79 illustrates the process steps of fabricating a one-piece prosthesis partially from in-vivo imaging data and partially from imaging data of impressions, merging those imaging data, design a prosthesis and a custom splint, and fabricating the prosthesis and the splint by computer numerical control (CNC) machining, according to an embodiment of the present invention.

[0142] FIG. 80 illustrates the process steps of fabricating a one-piece prosthesis from design data, completing the design by segmenting the prosthesis in a root portion that includes an abutment and a crown portion, fabricate the root portion by computer numerical control (CNC) machining, fabricating a negative shape of the crown portion as a mould by computer numerical control (CNC) machining, and use the root portion and the mould to complete the one-piece prosthesis shaping the crown potion, according to an embodiment of the present invention.

[0143] FIG. 81 illustrates an overall fabrication method of the prosthesis and its dedicated parts, including a splint, according to an embodiment of the present invention.

[0144] FIG. 82 illustrates the process steps of fabricating the custom splint from design data, and fabricating a model of the splint by rapid prototyping, build a mould around the splint, burning out the model and cast the splint by investment casting, according to an embodiment of the present invention.

[0145] FIG. 83 illustrates the process steps of clinically inserting a one-piece prosthesis into an extraction socket, positioning the prosthesis in relation to the adjacent teeth with the custom splint and fixating the prosthesis in relation to the adjacent dental structure with adhesive means, according to an embodiment of the present invention.

[0146] FIG. 84 illustrates a perforated splint comprising holes, according to an embodiment of the present invention.

[0147] FIG. 85 illustrates a splint which is attached only to one of the adjacent teeth, according to an embodiment of the present invention.

[0148] FIG. 86 illustrates a splint being attached to the adjacent teeth and teeth next to the adjacent teeth, according to an embodiment of the present invention.

[0149] FIG. 87 is a perspective and part environmental view of a customized elastic splint design/modification according to an embodiment of the present invention.

[0150] FIG. 88 is a perspective and part environmental view of a detachable two-part splint assembly according to an embodiment of the present invention.

[0151] FIGS. 89-90 provide a sectional view of the detachable two-part splint assembly of FIG. 88 according to an embodiment of the present invention.

DETAILED DESCRIPTION

[0152] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, which illustrate embodiments of the invention. The invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. Prime notation, if used, indicates similar elements in alternative embodiments.

[0153] Current methods for replacing damaged teeth have several disadvantages. For example, conventional bridge implants require healthy teeth to be ground, and traditional osseointegrated implants are drastically invasive. Additionally, these prostheses have a limited average lifetime. Removable dentures are the final prosthetic option. An object of the invention is to design and manufacture customized dental prosthesis for replacing human teeth and support structures and/or splints which provide primary stability until such time as secondary (long-term) stability is achieved.

[0154] Dental Prosthesis

[0155] FIG. 1 illustrates a method of replacing a human tooth with a customized dental prosthesis according to an embodiment of the invention. First, in step (A) a copy 31 of the natural tooth 33 to be replaced is fabricated. Then, in step (B) the natural tooth 33 is replaced with the prosthesis 31.

[0156] FIG. 2 shows a natural tooth embedded in its socket. The pulp 35 holds nerves and blood vessels 37. It is surrounded by dentine 39, which is covered on the top part of the tooth with enamel 41. The root portions have a thin layer of cement 43 providing connection to the ligament 45, which serves to anchor the tooth to the bone 47. The outside of the bone is covered with gum 49 that forms a seal with natural tooth to protect the ligament 45 and the bone 47.

[0157] According to an embodiment of the invention, portions of a dental prosthesis are individually shaped and integrated into the natural extraction socket of an individual specifically identified patient. The shape of the portions of the prosthesis representing the root can substantially copy the natural root of the tooth that was located in the socket. However, the shape may be modified in order to better adapt to the natural socket or to ease insertion of the prosthesis. Also, the socket may be surgically adapted for the same reasons. For example, damaged and infected soft tissue, tooth or bone substances would not allow for immediate or even delayed implantation.

[0158] An embodiment of the present invention includes the following steps: (i) Recording and digitizing (scanning) the three-dimensional anatomical shape of a human tooth or dentition; (ii) Obtaining a virtual model of the tooth as data record; and (iii) Manufacturing of the prosthesis, based on the three-dimensional data that have been obtained by the scan and if applicable, optimized.

[0159] FIG. 3 shows an example of process steps for intra-orally acquiring three-dimensional data of a human tooth, fabricating an artificial copy, extracting the natural tooth and replacing it with the artificial copy according to an embodiment of the invention. A CT scan (steps C, Q) is made of the dentition of the patient. The resulting data are volume based, where every numerical volume element (each called a voxel) represents the X-ray density of the corresponding natural volume portion of the dentition of the patient. The 3D voxel data are usually provided in a Digital Imaging and Communications in Medicine (DICOM) format. The volume data are converted into surface data, e.g. Surface Tesselation Language (STL) 3D data (step D), imported into Computer Aided Design (CAD) software and displayed to the operator (step E). The shape is modified and optimized as needed (step F). The resulting CAD 3D data is converted, for example, into the standardized Initial Graphics Exchange Specification (IGES) format and exported (step H) to a Computer Aided Manufacturing (CAM) system for fabricating the prosthesis (step I). The process may include coating the finished prosthesis (step J) with a substance promoting bone ingrowth (step K). Only after the prosthesis is ready for insertion, is the natural tooth extracted (step G), and the implant is placed into the extraction socket (step L). It should be noted that although FIG. 3 contemplates possibly interaction with an operator, one skilled in the art would readily appreciate that this functionality may be fully automated.

[0160] The data may either be recorded intra-orally from the patient, such as with a 3D camera, a micro laser optical device, a computerized tomography apparatus, or an ultrasound apparatus, or be recorded extra-orally by scanning an extracted tooth. If required, the model can be modified in order to ease insertion, divided and separated if the prosthesis is to be fabricated in components and assembled prior to insertion, or modified to receive aids for the final correct positioning of the fabricated prosthesis. The prosthesis can be fabricated as one piece or in components to be assembled prior to insertion. The prosthesis or its components can be directly produced by milling, grinding or rapid prototyping, for example, at a dentist's office or in a laboratory. It can also be produced using conventional laboratory procedures like casting. Preferably, the implant portion representing the root is manufactured using CAM methods, e.g., based on an acquired virtual model, while other portions of the prosthesis, for example, representing the crown or bridge, can be manufactured using standard procedures known in the art. Such methodologies, along with various others, are described in more detail, for example, in U.S. patent application Ser. No. 13/247,607, incorporated by reference in its entirety.

[0161] According to an embodiment of the present invention, a segmented prosthesis can be used. A segmented, also referred to a segment, prosthesis is one in which a first segment is implanted into the extraction socket and second segment, for example, a portion representing the crown of a tooth, is attached to the segmented portion. Accordingly, segmented prosthesis include at least two separate portions which may be manufactured and implanted at separate times. The segment which is implanted into the extraction socket can include a portion that is a representation of the root of the natural tooth and can be manufactured based on 3D imaging data. The segment representing the crown can also be at least partially manufactured according to 3-D imaging data and/or other processes according to standard procedures known in the art, and laminated or coated with an ecstatically pleasing material known to those of ordinary skill in the art.

[0162] In an embodiment of the present invention where the prosthesis will be positioned for osseointegration, INFUSE can be used to improve healing time and enhance the integration. Bone Graft (Medtronic Sofamor Danek) can be applied to stimulate bone formation. INFUSE Bone Grafts consists of two partsa solution containing rhBMP-2 (recombinant human bone morphogenetic protein 2) and the ACS (absorbable collagen sponge). The protein is a genetically engineered version of a natural protein normally found in small quantities in the body. The stimulation of bone formation is key to develop osseointegration, and to fill voids in between the extraction socket and the actual prosthesis in an accelerated manner. Other growth aiding proteins like bone morphogenetic protein (BMP), dentin matrix protein (DMP), platelet-derived growth factor (PDGF) and/or other bone growth stimulating proteins may be applied or otherwise used additionally or instead in order to facilitate integration, healing, and rebuild of the bone structure of the patient.

[0163] In another embodiment of the invention, cell attracting cytokines are attached or applied to the implant surface to be integrated. For example, that cytokine material InductOss (Wyeth) attracts bone building cells (i.e., osteoblasts) to enhance osseointegration. In contrast specific cytokine material can be applied to attract cementoblasts and/or fibroblasts to regenerate the perio-type membrane and avoid osseointegration.

[0164] In a further embodiment of the invention, cells (including but not limited to autologous and/or allogeneic cells) are attached or applied adjacent to or contained in a gel-type scaffold. Agarose gel scaffolds, platelet gel and/or fibrin (Baxter) based scaffolds are used. In order to create a geld type fibrin scaffold, the two components of fibrin sealant are mixed in a ratio 80:20 instead of 50:50.

[0165] A resin strip can be utilized to secure the prosthesis in place. An advantage of embodiments that employ osseointegration is that the complete replacement of the natural tooth can be performed in one appointment. After the prosthesis has healed in, only the resin strip initially securing the prosthesis to the adjacent teeth must be removed. A significant amount of laborious steps can thus be avoided. FIG. 4 shows an osseointegrated unsegmented tooth 31. Osseointegration is achieved in marked areas 50.

[0166] In yet another embodiment, the prosthesis will not be osseointegrated, but adopted by the ligament of the extraction socket. In this case the prosthesis is coated with a material promoting perio-type adoption. For example, a thin layer of about 0.05 mm to 0.2 mm of resin-modified glass-ionomer cement, for example, can be applied to the surface of the part of the workpiece being inserted into the extraction socket. Alternatively and additionally, substances promoting periodontal integration are applied, such substances include but are not limited to other types of natural tooth segments, natural tooth materials such as dentin, enamel and cementum (or a combination thereof), pharmaceuticals, ancestral cells, proteins, and cell parts of a human tooth. The substances can be in liquid, gel or powder form or provided as shavings or as any combination thereof, and the cells can be isolated or attached to separate scaffold material or to the implant surface, or a combination thereof. The meaning of ancestral cells shall include but shall not be limited to multi-potent and stem cells, as such cells have the ability to further differentiate. The meaning of cell parts of a human tooth shall include but shall not be limited to PDL-fibroblasts, non-PDL-fibroblasts, cementoblasts, osteoblasts and ancestral cells, having the ability to differentiate into PDL-fibroblasts, non-PDL-fibroblasts, cementoblasts and osteoblasts. PDL shall mean in this context periodontal ligament or perio-type ligament as applicable.

[0167] Especially in the context of perio-type integration, it might be advisable to utilize a Guided Tissue Regeneration (GTR) membrane, for example an absorbable collagen membrane, to separate the faster gum growth from the healing process of the periodontal ligament.

[0168] In another embodiment, an undersized customized root representation of a ceramic prosthesis is coated with a thin layer of mineral trioxide aggregate (ProRoot MTA, Dentsply) while potential socket irregularities are prepared with calcium sulphate (Capset, Lifecore Biomedical) in order to promote the selective formation of new perio-type tissue (i.e., cementum, perio-type ligament, Sharpey's fibers and alveolar bone) and to build a barrier against an overgrowth by gingival tissue. The thickness of the coating layer may match the undersizing of the root shape and would preferably be chosen to be about 0.2 to 0.3 mm. Alternatively, the outer shape of the root portion of the prosthesis and the coating thickness could still maintain an undersizing of substantial portion of the surface of the root portion compared to the shape of the natural tooth. It would furthermore be advantageous to insert the prosthesis into the socket as soon as possible, but no more than 24 hours (see respective reference re: Spouge, Oral Pathology, Mosby, Saint Louis, 1973 above), after extraction.

[0169] Perio-type integration (FIG. 5) has the advantage that the anchoring of the prosthesis 31 is not stiff as with osseointegrated implants, but shows the elasticity of the natural tooth. The soft tissue ligaments 45 are providing support to the teeth in a viscoelastic manner. Furthermore, forces applied to the tooth and thus, to the ligaments, create tension which is actually the stimulus for bone growth. Another function of the periodontal or perio-type ligaments is to serve as a method for tactile sensation. To support perio-type integration, the implantation of the prostheses should be performed shortly after extraction of the natural tooth, preferably not more than 24 hours after extraction. A key to success is the preservation of cellular vitality in the periodontal or perio-type ligament and performing the extraction in a surgical environment under conditions of asepsis. Further below, other embodiments of the invention are disclosed providing instant replacement of the natural tooth.

[0170] In another embodiment, not fully individualized per tooth and per patient, but suitable pre-determined generic root shapes can be selected and employed for fabricating the portion of the implant to be osseointegrated or integrated into the periodontal or perio-type ligament. A variety of generic shapes may be stored on a computer-readable media and accessed by the CAD/CAM system.

[0171] In yet another embodiment, the crown of the extracted tooth or the tooth to be extracted is not only subject to 3D imaging, but additional color data are obtained. Depending on the scanning method, color data can already be contained in the scan data, or a separate imaging is performed to record the color of the crown. It is possible to obtain a uniform overall color representing the average color of the crown, or alternatively, different shadings for different portions of the crown can be recorded. Based on the color data, the color of the crown can be adapted to the color of the original tooth. The lab technician manufacturing an artificial crown can, for instance, be provided with the color data and select the most appropriate color for the prosthesis. If a complete prosthesis is manufactured using CAM methods, a material best fitting the original color can be used, or a coating can be selected that matches the original color or even the individual pattern of colors.

[0172] In some cases the shape of the original roots will present difficulties on the insertion of the artificial replacement. For example, braided or divergent roots of a molar tooth or hocks and undercuts of roots need to be modified to allow for insertion. Also, the furcation can be modified in its vertical height or otherwise as prescribed by the doctor of record. In such cases, a proper modification and optimization of the shape of the artificial root according to FIG. 6 is applicable. In other cases, the root of the natural tooth may be suffering from partial root loss due to root resorption or a surgical procedure. In these cases or if otherwise prescribed by the doctor of record, the root of the replacement may be adapted to the extraction socket or even beyond as demonstrated in FIG. 7. For example, the customized portion includes a substantial copy of at least 60% of the root shape of the natural tooth while the other portion of the artificial root is modified as described herein. In other cases, the size of the socket may have been reduced over time due to root resorption as displayed in FIG. 8. The size reduction has occurred in areas 51. In such cases, it is advantageous to enhance anchoring by surgically enlarging the socket and to adapt the root of the artificial tooth to the enlarged socket. SolidWorks is a suitable CAD software to alter the shape of the implant with respect to the original imaging data.

[0173] There are more reasons to modify the shape of the implant with respect to the original root. To ease insertion into the extraction socket, the shape of the implant may be slightly undersized as shown in FIG. 9. MAGICS provides a functionality allowing for a simple reduction of the overall size of a body. This software has a couple of helpful features that have originally been developed to optimize plastic parts for injection molding, but turned out to be useful also for the processes of various embodiments of this invention.

[0174] In an exemplary embodiment, the root portion of the prosthesis adjacent to the bone socket of the extraction site substantially mimics either the root shape of the non-functional tooth to be replaced or the three-dimensional shape of the bone socket or any combination thereof, but will be dimensioned not to exceed the shape of the bone socket in order to avoid a conflict when positioning the prosthesis clinically in the pre-defined position and inclination. In a further embodiment, measurement and/or manufacturing tolerances are considered undersizing the root portion adjacent the bone socket in its design. Manufacturing tolerances are to be estimated between 10 and 50 micrometers. Measurement tolerances are to be estimated between 20 and 400 micrometers.

[0175] To achieve a long living prosthesis, the size and the shape of the root and the socket needs to be appropriate to enable solid anchorage in the bone. If, for example, a root is too small to absorb the normal chewing forces it may be necessary to expand the size of the socket before designing and manufacturing the customized root. Other patients may not have enough bone material or the outward facing lamella of bone (called bundle bone) does not have a thickness to maintain the bone structure after the extraction of the natural tooth, so that the thickness of the bone gingivally and labially is not sufficient for the anchorage of an implant, or to support the aesthetically expected clinical outcome. In such a case, the root may be shaped even smaller in corresponding areas of a critical bone lamella to allow for placing bone augmentation material known to those skilled in the art adjacent the implant into the extraction socket order to support a minimum thickness of bone (typically, a bone lamella that has a thickness of at least 1 mm is considered stable). This approach significantly increases the stability of the anchorage because no hollow or less stabile areas remain in the bone. If crown and root are manufactured as one part, the crown may be coated with an enamel-colored layer or multiple layers for aesthetic reasons. Such layer(s) can be, for example, translucent to a certain extent. During the healing process, appropriate measures need to be put in place to avoid early exposure of the implant to forces (bite bumpers, partials positioners, etc.).

[0176] The invention is not limited to the replacement of a single tooth. It is possible to manufacture dental bridges, whereby the lateral artificial teeth have root features that can readily be implanted into an existing socket. According to an embodiment of the present invention, the natural sockets 53 can be used as shown in FIG. 10 for attaching the bridge 55, with the adjacent teeth 33 staying healthy and complete. It is also possible to fabricate a partial prosthesis to be implanted into the natural socket, said prosthesis being the anchor for a later installment of a dental bridge. This embodiment is especially useful in cases where one of the two lateral supports of the bridge is already present, and the bridge therefore needs to be cemented.

[0177] According to various embodiments of the present invention, due to the ability of the suggested manufacturing processes, a respective embodiment of the invention allow the fabrication of prostheses representing crowns, roots, bridges, segments or any combination thereof, and also the entirety of a dentition.

[0178] In yet another embodiment, the artificial root will comprise a feature on its occlusal-facing surface shaped in a way that it allows for assembly of a conventional veneer or a pre-manufactured veneer or crown to the root. The occlusal-facing surface can also be shaped to provide an interlocking connection to the crown as shown in FIG. 11. The shape of the interlocking joint can have a straight geometrical contour (as shown in FIG. 11) or can be fully individualized to the patient's needs.

[0179] In another embodiment, the shape of the artificial root will not completely reflect the shape of the root to be replaced. In order to strengthen the connection with the perio-type or periodontal ligament or the bone, the shape will be modified. If, for instance, the three roots of a molar are located very close to each other, the three roots will be replaced by only one root which will comprise parts of the original shape of the three original roots.

[0180] According to an embodiment of the present invention, the prosthesis is manufactured in all its parts or as a single piece in its entirety before being integrated into the dental anatomy of the patient of interest. FIG. 12, for example, shows a tooth-shaped one-piece prosthesis having an integrated root portion and an integrated crown portion 31. The prosthesis 31 can be shaped with or without a custom shaped torus 57 that circumvents the prosthesis in a height of, for example, 0.5 mm below the line of gingiva 49. The torus 57 builds a barrier against in-growth of the gingival tissue. In case the prosthesis 31 is configured for osseointegration, the cavity in the bone 47 is virtually sealed, and osseointegration will take place without being disturbed by isolating lobes of gingival tissue growing between the prosthesis and the cavity. In case the prosthesis 31 is configured for perio-type integration, the gap between the prosthesis and the extraction socket is sealed against fast growth of gingival tissue, so that the integration into the perio-type or periodontal ligament structures, having a reduced growth rate in comparison, is protected.

[0181] In another embodiment as shown in FIG. 13, the prosthesis 59 has a sealing feature 61, which is circumventing or partially placed between the crown portion and the root portion of the prosthesis 59. The sealing feature 61 is either simply an indent (e.g. one or more circumventing grooves) or a labyrinth feature that builds the interface between the material of the prosthesis and the gingiva 49. The respective interface seals the structure between the prosthesis and the extraction socket against bacteria infiltration in order to gain long-term stability and to avoid pockets.

[0182] In another embodiment, the crown portion of a prosthesis is fabricated in an undersized shape compared to the final shape of the temporary or permanent crown of the prosthesis. Single or multiple layers of translucent ceramics are added in a laboratory process to gain esthetic performance compared to the appearance of a natural tooth. FIG. 14, for example, is a single tooth prosthesis having an undersized crown shape 31 and a build-up of several ceramic layers 63. It is also possible to use other esthetic materials having one or more than one layer. In another embodiment, the build-up 63 is, for example, made of elastic materials (like an elastic cover) in order to soften early contacts and foster in this way the healing process after integrating the prosthesis.

[0183] In yet another embodiment, the prosthesis includes a drug releasing surface, releasing over time medical substances. Such substances include, for example, one of the following: Antibiotic or other infection suppressing pharmaceuticals, growth promoting substances (for example, finally differentiated cells, ancestral cells, proteins, and cell parts of a human or animal tooth) or any combination thereof. FIG. 15 is, for example, a single-tooth prosthesis 31 having a drug releasing surface 65 covering at least a portion of the root part of the prosthesis 31.

[0184] In yet another embodiment, a prosthesis is fabricated based on imaging data of the patients dental anatomy. The imaging data includes three-dimensional representations of one tooth or two or more teeth. Each tooth includes a crown portion and root portion. The imaging data can be made either prior to or after extraction of the tooth or teeth to be replaced. The imaging data can include in-vivo data or data made in-vitro from one tooth or two or more teeth after extraction. Other imaging data are derived from physical impressions made of a dental anatomy. Dental anatomy includes the occlusion, the articulation, the geometrical (spatial) relationship between the teeth within one arch or between upper and lower arch of a patient, or parts thereof. Dental anatomy also includes the structures holding the tooth/teeth which include soft tissue structures and bone structures and any combination thereof. Imaging data can include two dimensional representations (for example, X-ray films, facial photos) or three-dimensional representations (like CT or MRT data). Imaging data can be any portion of the aforementioned data and/or any combination thereof. All these imaging data can be merged, overlaid and combined to derive shape data of a design of a prosthesis.

[0185] A further enhancement of the present fabrication process is shown in FIG. 16. Therein, two sets of surface-data are shown, i.e., surface-data of the crown portion 67 of the original tooth derived from the impression of the patient's denture and surface-data derived from the computed tomography image 69 providing information on the whole anatomy of the patient's non-functional tooth. It is to be noted that the uncertainty of the dataset provided by the impression lies at about 10 to 50 micrometer. The uncertainty of the dataset obtained from the computed tomography device shows an uncertainty within 200 to 300 micrometer. The impression data may include digital representations of the gum line surrounding the crown of interest.

[0186] Having these two types of surface-data, it is of interest to combine both datasets in the overlapping region 71, i.e., in the area of the crown portion. For this combination of datasets, the overlapping regions of the two datasets are placed together using best-fit algorithms. From the combination of the two datasets, a goodness/performance value of the fit is obtained as a value being calculated from the differences between the two datasets at corresponding points of the virtual prosthesis surface. Such a goodness value represents a measure representing the quality/performance of the fitting of the two datasets. For example, the sum of the distances raised to the second power could be used to calculate such goodness value of the best fit. From the combined dataset 73, the lower portion would represent the shape of lower accuracy derived from computed tomography data (image 69) while the upper portion 71 would represent the higher accuracy shape and the gingival line contour derived from the surface data of e.g. a digitized physical impression. From the combined data set 73 and the dataset 71, CNC-instructions are derived for the fabrication of the prosthesis or its components.

[0187] In the following, a procedure is described for enhancing the quality of the combined dataset. The proposed method/procedure executes the following steps: At first, the surface dataset derived from the impression (virtual crown) and the surface dataset derived from the computed tomography device data (virtual tooth with roots) are combined to one surface dataset of a virtual tooth. For this fitting combination a first goodness value is calculated that is saved electronically for further steps. Then, the surface data of the virtual tooth (combined dataset) is modified, e.g., blown up, biased, moved with respect to inclination and position etc. In a further step, the modified dataset of the virtual tooth is fitted to and combined with the original dataset of the impression. From this second combination of datasets, a second goodness value is derived. This second goodness value is saved electronically and compared to the aforementioned goodness value. If the new goodness value is greater, than the first goodness value, the aforementioned procedure is repeated. I.e., the second combined dataset is modified as before, e.g., blown up, biased, etc.

[0188] This iterative procedure (as shown in principle in FIG. 16) is repeated several times with different, e.g., systematically or randomly chosen modifications being applied to the respective combined dataset. In doing so, it is a goal to find or identify a maximum goodness value, e.g. employing the least-squares method in cases where the sum of the multiple local distances between corresponding portions of each data set, each raised to the second power, is used. For this search of the maximum goodness value, many kinds of statistical methods and mathematical optimization methods can be utilized in which the kind of modifications and the directions of modifications are derived from adaptive algorithms based on the kind of modification and its direction and the gradient of the quality (i.e., the goodness value) calculation the goodness value iteratively.

[0189] As shown, for example, in FIGS. 17A-17C, the shape design of mass-produced implants of a single tooth prosthesis 87 shows a standardized joint 77 between the implant 75 and the crown portion 78. While the crown is usually custom-shaped to the adjacent and opposite teeth, the implant 75 is not. Therefore, the joint between such traditional crowns and implants is non-customized. Such joints are usually shaped with standardized cylindrical, hexagonal, and conical shape portions, either concentric or symmetrically shaped in the vertical component of outward facing runout of the joint 77. E.g., the hexagonal rising 79 described to serve as prosthesis interface having a generic shape.

[0190] According to conventional methodology, in order to obtain a positive lock between the implant and the crown, numerous standard form joints are manufactured in order to try to cover a majority of the possible crown designs. This, however, results in significant additional manufacturing costs and difficulties in inventory management. Alternatively, a smaller number of standard designs are manufactured designed to cover most cases. Although the smaller number helps reduce inventory management problems and manufacturing costs, it has been found too often lead to inadequate joint connections and in increased number of collisions between components as the clinician is often provided an improperly fitting connection. That is, the joint having a smaller footprint than ideal is often employed in order to allow for adjustments due to the inadequate connection, or the occlusal raising does not support the anatomy of the crown to be placed thereon. Recognized, therefore, by the inventors is the need for a custom joint which can provide a good positive lock between the implant and the crown/intermediate abutment, and which can maximize the footprint between the connecting pieces. Also recognized by the inventors is that an optimal positive lock can be established by custom shaping the joint to reflect the general shape of the crown.

[0191] FIG. 18 illustrates a natural tooth having a natural enamel crown 81, a natural dentin root 83 and the natural juncture between dentin and enamel 85 showing an individual asymmetric outer contour line. FIGS. 17B-17C illustrate an implant 75 having a cross-section showing a cylindrical or respectively slightly conical screw portion having concentric convolutions or threads 87 and having an occlusally facing generic prosthetic interface including a symmetric and generic hexagonal rising 79, and showing a symmetric and generic scallop-shaped surface 89 having a symmetric and generic shaped edge 77 between the surface 89 and the concentric outer screw shape as an attempt to account for an anatomical 3D curvature of the gum line. Each of these features are shown in top view in FIG. 17C. FIG. 17A shows a prosthetic crown 75, which is affixed to the aforementioned hexagon rising (not shown in this view) of the prior art implant 87.

[0192] The inventors, however, recognize the limitations of such anatomically shaped mass-produced implant joint portion where a limited amount of standardized shape is supposed to fit all individual situations of the patients of interest in the limitations of utilizing a scallop-shaped surface having a symmetric and generic shaped edge to try to account for the anatomical curvature of the gum line.

[0193] Accordingly, various embodiments of the present invention provide apparatus and methods of manufacturing or otherwise providing a custom prosthesis interface having a three-dimensional surface shape positioned and formed to create a form locking fit with respect to the crown/abutment and the implant body, which can maximize or at least significantly increase the footprint of the locking fit, which can reduce and/or eliminate collisions between manufactured components, and which allows individualized stockingthus, eliminating the need to manufacture multiple potential versions of the joint. Various embodiments of the present invention also provide an asymmetrical shaped to account for the gum line.

[0194] The One-Piece Dental Implant/Prosthesis

[0195] FIG. 19 illustrates a cross-sectional view of an exemplary embodiment of a one-piece dental prosthesis 95. The term one-piece refers to the root body 91 portion and the crown cap 93 which are assembled as a one piece body 95. The body 91 is mainly composed of a ceramic material. This ceramic material as described herein can be pure zirconia, or a ceramic matrix composite like yttria-stabilized (tetragonal phase) zirconia (e.g., Y-TZP zirconia, NaceraZ Medium/Ivory, Doceram), alumina-toughened zirconia (e.g., ATZ zirconia, ZIRALDENT, METOXIT) or zirconia-toughened alumina. On the top of the one piece body 91, a translucent cap, the crown cap 93 made of feldspar ceramics, lithium disilicate ceramics, highly translucent yttria-stabilized (tetragonal phase) zirconia, or resin nano ceramic technology materials (e.g., IPS e.max CAD HThighly translucent, IPS e.max CAD LTlow translucent, available in various color shades, Ivoclar Vivadent, Z-CAD HTL, METOXIT, Lava Ultimate, 3M ESPE), is placed and attached with adhesive means at 97. This is, for example, a temporary silicon based adhesive (e.g., TempoSIL2, coltne whaledent), a temporary non-silicon based adhesive (e.g., eugenol-free cement, e.g., RelyX Temp NE, 3M ESPE) for temporary use, or a permanent cementation (e.g., RelyX Unicem, 3M ESPE) for definite use. The spacing between the one piece body 91 and the translucent glass cap 93 can be adjustable depending on the adhesive material used for the attachment of the crown cap 93 onto the ceramic body 91. In an exemplary embodiment, the gap is 100 microns. An advantageous range is between 50 and 200 microns. In an alternative embodiment, for example, when non resin materials are used for the crown cap 93, the adhesive material at 97 can be composed of glass solder (e.g., Hotbond Tizio silicate coating and Hotbond Plus, DCM), where the parts are fused together utilizing a hot-bond process. In the process of integration, the one-piece dental prosthesis 95 can be placed into the alveole as a whole. Note, this is in contrast to procedures used with state of the art dental implants where a root portion is integrated and in a further step a crown portion is attached to the root portion. In order to prepare the surfaces of interest for non-fused connection, a cold-processed tribochemical method for silicatising surfaces may be applied (e.g., Rocatec Plus by 3M ESPE). The silicatised surface is prepared for bonding (e.g., cementing) by applying a silanising surface conditioning, i.e., a silane resin primer (e.g., ESPE Sil, 3M ESPE). Crown caps are traditionally individualized by manual manufacturing processes or directly or indirectly machined to fit the pre-existing preparation of a post stumps (on implants, implant assemblies, or natural teeth) prepared by the dentist inside the mouth or a patient. It has not been recognized until now by the inventors, however, that the occlusually-facing surface 101 of the actual implant body 91 can be optimally individualized prior to clinical insertion. This can be even of advantage when the rest of the shape of the implant body 91 is of generic shape, e.g. a traditional screw type dental implant. Further, it has not been recognized until now by the inventors that the apical-facing surface 103 of the crown 93 can machined responsive to data free-form created in a CAD system.

[0196] In an exemplary embodiment, a hot processed glaze finish (e.g., Crystall/Glaze and Crystall/Glaze Liquid, Ivoclar Vivadent) is applied to the non-resin translucent crown cap 93 prior to temporary or permanent bonding. Usually, a crown is bonded in the patient's mouth in the dentist's office. In an exemplary embodiment of the invention, the bonding takes place at the site of the manufacturer to thereby increase accuracy and the quality of the bonding itself.

[0197] Koebel et al. disclose in WO 2008/017472 a rough, porous osseoconductive topography of a zirconia implant surface that promotes bonding between the implant and tissue, where in a mixture, comprising of a polymer and at least one ceramic material is applied on a substrate, the mixture further comprising inorganic binders, e.g., phosphates, silicates, carbonates, sulfates. However, it has not been recognized until now by the inventors that dental implants, abutments, prostheses or parts thereof are individualized in its three-dimensional shape prior to such surface coating.

[0198] As noted above, the exemplary prosthesis 95 has an anatomically custom-shaped edge to the cross-section 99 adjacent the gum line, where the root-shaped outer surface portion corners to an occlusually-facing interface portion 101 to receive the crown cap 93. The joint line of the juncture 97 between the implant body 91 and the crown cap 93 shows in the cross-sectional view an individual, asymmetrical custom-shaped rising over the circumferential edge 99 curvature in the occlusal direction of the main longitudinal axis of the prosthesis. The occlusually-facing surface 101 of the implant body 91 correlates in its three-dimensional shape to the corresponding interface surface 103 of the crown cap 93, together creating a form-locking fit. Further, in an embodiment of the prosthesis, the individual, custom-shaped curvature of the outer joint (partially shown in the cross-sectional view as edge 99) is designed and manufactured to substantially follow either adjacent the gum line of the gingiva 105 of the patient or parallel to a bone crest shape, or a combination thereof

[0199] The design process of both the implant body 91 and the crown cap 93 includes deriving from clinical imaging data representing the bone crest and/or the gum line, the virtual representation (i.e., the custom design) of the adjacent joint surface shapes 103 and 101 of the virtual representations of the implant body 91 and of the crown cap 93. In another method step, numerical machine control data are derived from the custom design of the joint shape and parts are machined (or made otherwise by rapid prototyping technologies) based on such numerical machine control data, the parts having physical joint shapes substantial to virtual custom design data.

[0200] According to the illustrated embodiment, the customized joint interface 97 between the implant body 91 and the crown cap 93 comprises a customized three-dimensional shape, i.e., a three-dimensional surface that separates the crown portion 103 from the root portion 101. In contrast to conventional joints between an detachable abutment and a crown, the illustrated joint is a customized joint actually between the implant body 91 itself and the crown cap 93, where at least the occlusally-facing interface member 101, manufactured prior to clinical insertion of the implant body 91, individually correlates to the dental anatomy of the patient's tooth to be replaced and the adjacent dental structures, including the gum lime, the bone socket, the adjacent and/or opponent crowns. This means that the points of separation along the juncture gum 105 at the intersection between the root portion i.e. the implant body 91 and the crown portion i.e. the crown cap 93 are individually designed, and in most cases, asymmetrical, instead of showing a generic symmetrical shape. Moreover, the course of the joint is individually form-fitted to the patients need and potential geometrical limitations and to complement the form of the crown cap 93 to be placed on the implant body 91. In an embodiment, the interfaces between such parts are sealed in order to provide a barrier against bacteria infiltration.

[0201] A problem occurs when both the implant body 91 and the crown cap 93 are fabricated in a parallel process. Both the implant and crown are fabricated based on data obtained from the scan and impression of the original denture. The customized joint interface 97 is then designed for both parts based on the aforementioned data. In such a parallel fabrication process however, small fabrication failures and inaccuracies can lead to two joint portions (i.e., two three-dimensional surfaces of the implant body and the crown portion) that in some cases do not totally fit together. This is especially an issue when the two parts are both made of hipped (HIP) zirconia since only small corrections can be applied to such a material. In an exemplary fabrication method of the aforementioned prosthesis 95, the implant body 91 and the crown cap 93 are instead fabricated in a serial fabrication process. Therefore, in a first step, the implant body 91 is fabricated with a customized surface forming the root portion and the joint portion 101. In a further step, the three-dimensional surface is scanned or an impression prior to clinical insertion is taken, thereby, acquiring data that actually represents the embodiment of the customized joint as it is embodied in the fabricated implant body 91. The data obtained from the scan of the customized joint 97 is then utilized for the fabrication of the crown cap 93 interface member 103 having a customized joint portion that fits to the joint portion 101 of the implant body 91 with a high accuracy.

[0202] In contrast, in a common process using CAD/CAM technologies to make dental crowns and bridges, the process receives the custom shape of the tooth preparation to form the joint between the natural tooth or even of a custom shaped abutment. Such joint shapes, however, are not custom generated or designed (i.e., originated) in the virtual domain, but rather are physically man-made and shaped by the doctor of record in the mouth of the patient of interest. Even when new state-of-the-art abutments having the transgingival middle-pieces that connect the implant screw with the crown are custom shaped with respect to the outer shape that finally receives the crown, the implant facing joint/interface surface of such abutment is of a three-dimensional standard (i.e., non-custom) geometry.

[0203] FIG. 20A shows a proximal lateral view of a dental prosthesis 107 having a crown portion 109 and a root-shaped implant body 111, being separated at a junction that shows up as a circumferential line 113 in the view of the figure. FIG. 20B also shows a cross-sectional lateral view 115 of the dental implant body 111. In the cross-sectional view 115 of the implant body 111, illustrating that the surface line 117 of the occlusally facing surface is asymmetric, having a different slope or steepness on one side compared to the slope or steepness of the other one side. In the proximal lateral view, the circumferential line 113 is also asymmetrical, having a different slope or steepness in the direction of the labial height of the line at 119 compared to the slope or steepness in the direction of the lingual height of the line at 120.

[0204] FIG. 21 illustrates a cross-sectional view of another exemplary embodiment of the present invention. The implant body 131 of the prosthesis 121 has an anatomically custom-shaped edge to the cross-section 123 adjacent the gum line of the gingiva 125, where the root-shaped outer surface portion of the implant body 131 corners to an occlusually-facing interface portion 127 to receive the crown cap 129. The joint line of the juncture between the implant body 131 and the crown cap 129 shows in the cross-sectional view an individual, asymmetrical custom-shaped indent over the circumferential edge 123 curvature in the apical direction of the main longitudinal axis of the prosthesis. The occlusually-facing surface 127 of the implant's body 131 correlates in its three-dimensional shape to the corresponding interface surface 133 of the crown 129, together creating a form-locking fit. Further, in an embodiment of the prosthesis, the individual, custom-shaped curvature of the outer joint (partially shown in the cross-sectional view as edge 123) is designed and manufactured to follow either substantially adjacent the gum line of the gingiva 125 of the patient or substantially parallel to a bone crest shape, or any combination thereof.

[0205] Designing the One-Piece Dental Implant/Prosthesis

[0206] FIGS. 22-27 illustrate an example of a method of designing the one-piece dental implant 95 (shown in FIG. 19) formed of two major pieces to replace a non-functional natural tooth 135 positioned in a jawbone of a specific pre-identified patient. As shown in FIG. 22 the one-piece and two-piece design methods can include the steps of receiving data describing a three-dimensional X-ray image 137 of at least portions of the patient's dentition (x-ray image data), and receiving data describing a surface scan of a dental anatomy and/or a physical impression of the dental anatomy at 139, defining impression image data made prior to removal of the non-functional natural tooth from the jawbone of the specific patient. The steps can also include forming one or more three-dimensional virtual models at 141 of at least portions of the non-functional natural tooth 135, for example, by combining the x-ray image data of the x-ray image 137 (including the location of the bone crest line/bone-facing gum line 143) and impression image data of the surface impression image at 139 (including the location of the outer gum line 145), and forming the three-dimensional virtual model or models at 141 of the non-functional natural tooth 135 to include a modeled virtual root portion 147 and a modeled virtual crown portion 149 modeled or otherwise designed based upon to the x-ray image data of the x-ray image at 137 and the impression image data of the surface impression image at 139.

[0207] FIGS. 23-27 further detail exemplary steps of designing the one-piece dental implant based upon the three-dimensional virtual model 141 of at least portions of the non-functional natural tooth 135. The steps of designing the dental implant include the steps of forming a virtual dental implant body 151 (FIG. 27) modeling a physical dental implant body having a virtual prosthesis interface at 153 (FIG. 26) modeling a physical prosthesis interface of the physical dental implant body to receive an occlusally-facing dental prosthesis component 163. The step of forming a virtual dental implant body 151 can include forming the virtual prosthesis interface (at 153, FIG. 26) to have a three-dimensionally contoured implant body surface shape at least partially correlated to a surface shape of an occlusally-facing surface of the modeled virtual crown portion 149 and crown surface of the nonfunctional tooth 135.

[0208] As perhaps best shown in FIG. 22, according to an exemplary one-piece, two-part dental implant body configuration, the step of forming a virtual dental implant body 151 can include separating a portion of the three-dimensional virtual model (including the modeled virtual root portion 147 and modeled crown portion 149) along a virtual outer gum line representation 145. Note, according to the illustrated configuration, the separation/transformation procedure performed on virtual model at 141 can include both digital cutting and digital thickening of the components 147 and/or 149 to the inside while maintaining the dimensional integrity of the outer surface. For the two-piece example, this results in the root portion 147 having a non-infinitesimal thickness as shown, i.e., having a thickness of a substantial dimension. The virtual root portion 147 shown in FIG. 23 is represented in digital surface data format e.g., STL, is defined by an outer shell 155, an inner shell 157, and an occlusally-facing connecting surface 159. The design process step of thickening, generally employed in both two-piece and the three-piece configurations, creates an inner (smaller) second shell, and then generates the surface boundary that shows the thickness.

[0209] As perhaps best shown in FIGS. 24 and 26, the step of forming can also include copying at least portions of the modeled virtual crown portion 149 to form a base shape of the virtual prosthesis interface, reducing dimensions of the at least portions of the modeled virtual crown portion 149 to define a virtual prosthesis interface model at 161, and as shown in FIG. 26, combining the virtual prosthesis interface model 161 having reduced dimensions with the virtual root body portion model 147 to form the virtual dental implant body 151 having a virtual prosthesis interface 153.

[0210] As shown in FIGS. 24-25, according to this configuration, the steps can also include forming the virtual occlusally-facing dental prosthesis component 163 (FIG. 27) modeling an occlusally-facing dental prosthesis component, such as, for example, a virtual crown component 163. According to such configuration, the step of forming the virtual crown component 163 includes forming a complementing virtual dental implant body-receiving (interface) surface 165 (FIG. 25) modeling a physical complementing interface surface to receive occlusally-facing portions 153 of the dental implant body 151 to create a form locking fit therebetween. This can be accomplished by copying at least portions of the modeled virtual crown portion 149 to form a base shape of the complementing interface surface 165 of the virtual crown portion 163, reducing dimensions of the at least portions of the modeled virtual crown portion 149 to form the complementing interface surface model shown at 167 (FIG. 24), and combining the virtual crown portion model 149 with the complementing interface surface model 167 as shown in FIG. 25 to form the virtual crown portion 163 shown in FIG. 27. Note, the virtual crown component 163 (FIG. 27) can extend in the apical direction to, for example, the virtual outer gum line representation 145 (FIG. 23). Also, the aforementioned step of combining the virtual crown portion model 149 with the complementing interface surface model 167 as shown in FIG. 25 to form the virtual crown portion 163 shown in FIG. 27, can include a design step to close potential gaps between the two outward-facing interface shells that form substantially the virtual crown component 163 (FIG. 27).

[0211] As shown in FIG. 24, the dimensions of the complementing interface surface model 167 is reduced by the material thickness of the crown cap (at least 0.5 mm in thickness in this example) to be by this amount smaller than the dimensions of the virtual crown portion 149, and the dimensions of virtual prosthesis interface model 161 is reduced to be smaller than the dimensions of the complementing interface surface model 167. These dimensional reductions in the three-dimensional size of the pairs of surfaces 167 and 161 that build an interface and/or form the form-locking fit, are to account for manufacturing tolerances and to account for a certain thickness of the layer of adhesive, cement or glass solder, etc., generally in the range of 50 to 300 micrometers, but preferably approximately 100 micrometers.

[0212] The Compound Dental Implant/Prosthesis

[0213] FIG. 28 shows a cross-sectional view of a single tooth prosthesis 170 which is a variant of the embodiment of the dental prosthesis shown and described in context of FIG. 19 and shows a compound one-piece prosthesis with a first joint between an implant body 169 and a transgingival cap 171 and a second joint between the transgingival cap 171 and a crown 172. The partially root-shaped implant body 169 matches the extraction socket 173 of a pre-identified patient, without interfering with or intruding into the surface socket itself. The implant body 169 is formed of, for example, commercially pure titanium (e.g., medical grade 2 commercially pure titanium) or a medical-grade titanium alloy (e.g., Ti.sub.6Al.sub.4V). The middle piece, the transgingival cap 171, is made, for example, of ceramic material e.g., Y-TZP zirconia or ATZ zirconia, and serves a similar purpose of an abutment in traditional dental implantology. In an exemplary embodiment, the transgingival cap 171 is favorably tooth colored, e.g., in its white body state, prior to final sintering by volumetric coloring (e.g., color liquid e.g., Zirkon B4; C3; D4, Zirkonzahn).

[0214] Further, in the exemplary embodiment, the implant body 169 and the transgingival cap 171 are fused together by the above described hot-bond technology, where the titanium surface of the interface 175 is first silcatized by a coating applied in a heating process (e.g., Hotbond Tizio silicate coating), then the two parts of interest 169 and 171 are glass soldered (e.g., Hotbond Plus, DCM), building together a fused extended implant body. In addition, the zirconia surface of the interface 183 can also be first silcatized by a coating applied in a heating process (e.g., Hotbond Zirconnect silicate coating). The outer joint line (shown as an edge 177) in the cross-sectional view of the joint 179 is sub-gingivally positioned (typically at bone crest level or even partially intra-crestal) and the transgingival cap or abutment portion 171 is permanently fused and sealed reducing significantly the risk of an opening or gaping under load, and of bacteria colonization at the interface, compared to traditional implants. The interface between the transgingival cap and the crown at 99 is discussed in the context of FIG. 19. Although state-of-the-art abutments are partially customized in its outer interface surface 181, it has not been recognized until now by the inventors that the interface pairs 175 and 183 at the junction 179 can be to the patient's needs individually designed in a computer and subsequently fabricated to numerical data derived from that virtual interface design.

[0215] The embodiment of FIG. 28 has two fully custom-shaped joints or interfaces, the one 179 positioned sub-ginivally, e.g., at the bone crest level, and the second 181 positioned iso- or supra-gingivally. Each pair of surfaces that build the two prosthetic interfaces (175 and 183) and (181 and 185) create a form locking fit. The respective three-dimensional surfaces (shown as cross-sectional view) dimensionally correlate with the outer three-dimensional shape 187 of the crown 172 and dimensionally correlate with each other. According to the exemplary configuration, the design of the shapes of both joints is created or originated in the virtual domain using the digital data representing the anatomical specifics of interest. There is a minimal thickness of 0.2 mm to 0.5 mm (typically 0.3 mm) to be considered for the middle-piece i.e., the transgingival cap 171. In the exemplary configuration, the outer joint line of the interface between the implant body 169 and the transgingival cap 171 (shown in the cross-sectional view as edges 177) follows the saddle shaped 3D curvature of the bone crest adjacent the anatomical socket, while the outer joint line of the interface between the transgingival cap 171 and the crown 172 shown in the cross-sectional view as edges 99 follows the saddle shaped 3D curvature adjacent the gum line of the gingiva 105.

[0216] Again, this is not a standard curvature of a cylindrical mass-produced implant. To the very contrary, this design is individually performed per specific tooth of a pre-identified patient. The shape data are derived from clinical images of the dental anatomy of such patent. In this specific context, the design takes into account, the anatomical cross-section of the implant body 169 substantially matching the shape of the extraction socket, or matching the root of the tooth being extracted, and substantially perpendicular to that cross-section, the 3D curvatures of the two joints between the three parts (e.g., made of different materials) in the longitudinal axis of the dental tooth prosthesis. The substantially parallel gap between the two adjacent surfaces that build the interface is between about 100 microns and 300 microns (typically 200 microns) to accommodate a minimal thickness of the glass solder for the sub-gingival joint and for the cement for the iso- or supra-gingival joint. In a further exemplary embodiment, the shape of the surfaces of each joint extend the outer joint line to the occlusal plane (i.e., in the direction of the tip of the crown 172) to accommodate for a maximum stability for the assembly to withstand mastication forces. Note, applicable descriptions of FIG. 19 apply to the descriptions of FIG. 28 and vice versa.

[0217] FIG. 29 shows an exploded view of a dental prosthesis having a crown 189, a trans-gingival portion 191, and an implant body 193, along with a splint 195. FIG. 29 further shows, for example, in principle, the three-dimensional extensions of the surfaces shown in cross-sectional view in FIG. 28 (although FIG. 28 represents exemplarily a dental prosthesis to replace a molar tooth, while FIG. 29 represents an exemplarily dental prosthesis to replace a premolar tooth). According to the illustrated configuration, each transversal and lateral cross-section of the components 189, 191, 193 and 195 are custom-shaped, having an individual three-dimensional shape that is substantial asymmetric, does not include generic concentric shapes, does not include generic symmetric shapes, and does not include convolutional shapes. The respective form-locking fit of the prosthetic interfaces between surfaces 197 and 199 and between surfaces 201 and 203 is clearly indicated for those skilled in the art. The outer circumferential edge 205 of the surface 203 varies in the direction of a mainly longitudinally axis of the implant body 193 and in transversal direction with respect to the distance to such longitudinal axis. For those skilled in the art, it is clearly indicated that the three-dimensional shapes of the aforementioned interface surfaces correlate with the outer surface of the crown 189 and with each other. The maximal transversal dimension of the implant body 193 adjacent the outer circumferential edge 205 is significantly bigger than the minimal transversal dimension of the implant body 193 adjacent the outer circumferential edge 205. In an alternative exemplary embodiment, the crown 189 and the splint 195 are integrated as one piece to form an integrated support device (described in detail later).

[0218] FIG. 30 shows a labial view of a dental implant prosthesis 206 having an artificial crown portion 207 made of a translucent material colored at least similar to the color of a natural crown mimicking the shape of the natural enamel crown 81 of FIG. 18. The dental implant prosthesis 206 also has an artificial root portion 208 including an opaque material suitable for tissue integration and substantially mimicking the shape of the natural dentin root 83 of FIG. 18. The artificial crown portion 207 and artificial root portion 208 have a junction that shows in the view of the figure as a circumferential line 209 so that the runout of that juncture at 209 follows the natural juncture between dentin and enamel 85 shown in FIG. 18. In the labial view of the prosthesis 206, the circumferential line 209 is asymmetrical, having a substantially different slope or steepness in the direction of the proximal height of the line on one side 210 and to the slope or steepness in the direction of the proximal height on the other one side 211. In an alternative exemplary embodiment, the artificial crown portion 207 is in the form of either a temporary crown or a portion of an integrated support device (described in detail later) whereby the bonding wings to affix the integrated support device to one or more adjacent teeth are not shown.

[0219] FIG. 31 shows a cross-sectional lateral view of the dental implant prosthesis 206 having a crown portion 207 and a root portion 208 being shown separated at a junction 213. In the cross-sectional view of the prosthesis, the correlating surface lines that build the form locking fit of junction 213 are asymmetric, having a different slope or steepness on one side compared to the slope or steepness of the other one side.

[0220] FIG. 32 shows a top view 215 and cross-sectional transversal view 217 of a dental implant body 219. The maximal transversal dimension of the implant body shown in the top view is significantly bigger than the minimal transversal dimension of the implant body shown in the top view. Its outer circumferential contour is asymmetric as shown in top view. The cross-sectional view 217 indicates a transversal cross-section of the male portion surface 221, i.e., a positive rising, of the prosthesis interface that creates a form-locking fit to an occlusally facing prosthesis component (as shown for example, in FIG. 30). The maximal transversal dimension of the implant body shown in the cross-sectional view 217 is significantly bigger than the minimal transversal dimension of the implant body shown in the cross-sectional view. Its outer circumferential contour is asymmetric as shown in top view, and correlates in its shape and orientation to the outer shape of the top view 215.

[0221] Designing the Compound Dental Implant

[0222] FIGS. 33-39 illustrate an example of a method of designing the compound one-piece dental implant 170 (shown in FIGS. 28 & 39) formed of three primary pieces, based upon the three-dimensional virtual model 141 of at least portions of the non-functional natural tooth 135 (as already referenced in FIGS. 22 and 23). According to an example of the three-piece dental implant body configuration, as perhaps best shown in FIG. 33, the step of forming a virtual dental implant body 223 (FIG. 38) includes separating a portion of the three-dimensional virtual model 141 along the virtual bone-facing gum line representation 143 to form a modeled virtual root portion 225 and a first modeled virtual crown portion 227 (used to form the modeled transgingival cap portion), and copying a portion of the modeled crown portion of the virtual model 141 separated at the outer gum line 145 to form a second virtual crown portion model 229 modeling the physical crown.

[0223] As perhaps best shown in FIG. 34, the step of forming the virtual dental implant body 223 (FIG. 38) further includes copying at least portions of the modeled first virtual crown portion 227 to form a base shape of the prosthesis interface 231 (FIG. 38 and reducing dimensions of the at least portions of the modeled first virtual crown portion 227 to define a prosthesis interface model 235. As shown in FIG. 35, the step of forming also includes combining the virtual prosthesis interface model 235 with the virtual root body portion model 225 to form the virtual dental implant body 223 (FIG. 38).

[0224] As shown in FIGS. 34, and 36-38 , the steps can also include forming a virtual occlusally-facing dental prosthesis component modeling an occlusally-facing dental prosthesis component, such as, for example, a virtual crown component 237 (FIG. 38) and/or a virtual transgingival cap component 239 (FIG. 38). The virtual crown component 237 can be formed by employing the procedures described with respect to forming the virtual crown component in the two-piece configuration, to include copying at least portions of the modeled virtual crown portion 229 to form a base shape of a complementing interface surface 241 (FIG. 37) of the virtual crown portion, reducing dimensions the modeled second virtual crown portion 229 to at least support minimal material thickness requirements of between approximately 0.2 mm to 0.5 mm (typically 0.3 mm) to form the complementing interface surface model shown at 243 (FIGS. 34 and 37, and as shown in FIG. 37, combining the virtual crown portion model 229 with the complementing interface surface model 243 to form the virtual crown portion 237 (FIG. 38). Note, the virtual crown component 237 (FIG. 38) extends in the apical direction to, for example, the virtual outer gum line representation 145 (FIG. 33). Note also, the aforementioned step of combining virtual crown portion 229 with the complementing virtual interface surface model 243 includes a design step to close potential gaps between the two outward-facing interface shells that form substantially the virtual crown component 237 (FIG. 38).

[0225] As shown in FIGS. 34 and 36, the transgingival cap can be formed using a similar set of procedures. For example, the step of forming the virtual transgingival cap component 239 (FIG. 38) can include forming a complementing virtual dental implant body receiving (interface) surface 245 (FIG. 36) modeling a complementing interface surface to receive occlusally-facing portions of the dental implant body, and forming a complementing virtual dental crown body receiving (interface) surface 247 (FIG. 36) modeling a complementing interface surface to receive apically-facing portions of the dental crown body. This can be accomplished by: copying at least portions of the first modeled virtual crown portion 227 (modeling the transgingival cap portion cut along the bone-facing gum line representation 143) and reducing dimensions of the at least portions of the modeled first virtual crown portion 227 to define an interface model 249 to form a base shape of the complementing interface surface 245 to thereby form the occlusally-facing surface of the virtual transgingival cap portion 239; reducing dimensions of the at least portions of the first modeled virtual crown portion 227 modeling the transgingival cap portion shown at 247 by reducing dimensions of the at least portions of the first modeled virtual crown portion 227; and combining the virtual transgingival cap model 247 with the complementing interface surface model 249 to form the virtual transgingival cap 239 (FIG. 38). Note, the virtual transgingival cap 239 (FIG. 38) extends in the apical direction to, for example, the bone-facing gum line representation 143 (FIG. 33). Note, the aforementioned steps of reducing the virtual transgingival cap model 247 and reducing the complementing virtual interface surface model 249 are coordinated to the extent to account for a minimal material thickness of approximately between 0.2 mm to 0.5 mm (typically 0.3 mm). Also, the aforementioned step of combining the virtual transgingival cap model 247 with the complementing virtual interface surface model 249 includes a design step to close potential gaps between the two outward-facing interface shells that form substantially the virtual transgingival cap 239 (FIG. 38).

[0226] Note, the dimensions of the transgingival cap portion model 247 is reduced to be smaller than the dimensions of complementing interface surface model 243, and the dimensions of virtual prosthesis interface model 235 is reduced to be smaller than the dimensions of the complementing interface surface model 249. These dimensional reductions in the three-dimensional size of the pairs of surfaces that build an interface and/or form the form-locking fit are to account for manufacturing tolerances and to account for a certain thickness of the layer of adhesive, cement or glass solder, etc., generally in the range of 50 to 300 micrometers, but preferably approximately 100 micrometers.

[0227] Interlocking Compound Dental Implant/Prosthesis

[0228] Various embodiments of the present invention include a single tooth prosthesis 400, shown in partially cross-sectional view in FIG. 40, and in perspective view in FIG. 41, which is a variant of the embodiment of the dental prosthesis shown and described in context of FIGS. 19, 21 and 28. According to the exemplary configuration, prosthesis 400 includes an implant body 401 (see also FIG. 42), a transgingival interlock abutment 403 (see also FIG. 43), and a occlusal-facing prosthesis componente.g., a crown 405 (temporary and/or permanent) and/or an integrated support device (described later) or other dental prosthesis component. In the illustrated embodiment, the at least partially root-shaped implant body 401 at least substantially matches the extraction/implantation socket 407 of the jawbone of a pre-identified patient, generally without interfering with, or intruding into, the surface of the socket itself

[0229] According to the exemplary embodiment, the implant body 401 is formed of, for example, commercially pure titanium (e.g., medical grade 2 commercially pure titanium) or a medical-grade titanium alloy (e.g., Ti.sub.6Al.sub.4V). According to the exemplary configuration, the middle piece, the transgingival interlock abutment 403, shown in perspective view in FIG. 41, is made, for example, of ceramic material e.g., yttria stabilized polycrystalline tetragonal zirconia (Y-TZP ZrO.sub.2) or ATZ zirconia. In an exemplary embodiment, the transgingival interlock abutment 403 is favorably tooth colored, e.g., in its white body state, prior to final sintering by volumetric coloring (e.g., color liquid e.g., Zirkon B4; C3; D4, Zirkonzahn). The crown 405 can also be ceramic and/or ceramic having a layer simulating enamel as known to those of ordinary skill in the art. Other crown materials discussed above can be used alternatively.

[0230] According to the embodiment illustrated in FIGS. 40 and 41, the prosthesis 400 has two fully custom-shaped joints or interfaces 411 and 412. A first joint 411 located between the implant body 401 and the apical extending rising 413 of the transgingival interlock abutment 403 is generally positioned sub-gingivally, e.g., at the bone crest level, and the second joint 412 located between the occlusal extending rising 415 of the transgingival interlock abutment 403 and the crown 405 is generally positioned iso- or supra-gingivally, or adjacent to the outer gingival line at 421 and at 422, when the prosthesis 400 is operably positioned within the jawbone of the pre-identify patient. An advantage of such exemplary design or designs includes providing a ceramic abutment that is no longer a fragile, but rather, a massive solid. Additionally, an advantage includes an elimination of the risk that gray metal (titanium) shines through what would be a relatively thin crown portion.

[0231] The figure details an example of the contour lines of the apical and occlusal joints 411, 412, as presented in a cross-sectional view of the prosthesis 400. According to the illustrated embodiment, the cross-section of the occlusal joint 412 shows a rounded run-out 421, 422, at the perimeter of the joint facing bonding surfaces 423, 424, where the local cross-sections of the opposing parts perpendicular to the perimeter line have a stable material edge of approximately 90 degrees. The cross-section of the apical joint 411 shows an angled run-out 431, 432, at the perimeter of the joint facing bonding surfaces 433, 434, where the local cross-sections of the opposing parts perpendicular to the perimeter line have a stable not-sharp material edge of the ceramic part of more than 90 degrees, while the corresponding titanium implant body part has a sharp edge of less than 90 degreespreferably 135 degrees for the ceramic part and 45 degrees for the titanium part. This can beneficially provide utmost fracture toughness for the ceramic part, while the titanium material is not undermined by the sharp run-out.

[0232] Further beneficially, each pair of surfaces that build the two prosthetic interfaces 423, 424 and 433, 434, each create a form locking fit. The respective three-dimensional surfaces 423, 424 (shown as cross-sectional view) dimensionally correlate with the outer three-dimensional shape of the crown 405 and dimensionally correlate with each other. The respective three-dimensional surfaces 433, 434 (shown as cross-sectional view) dimensionally correlate somewhat with the outer three-dimensional shape of the implant body 401 and dimensionally correlate with each other. According to the illustrated embodiment, the three-dimensional surface shape of the occlusal extending rising 415 includes a substantial asymmetric negative indent 425 recessed into the occlusal facing surface of the occlusal extending rising 415.

[0233] According to the exemplary configuration, the design of the shapes of both joints is created or originated in the virtual domain using the digital data representing the anatomical specifics of interest. In the exemplary configuration, the outer joint line of the interface between the implant body 401 and the transgingival interlock abutment 403 (shown in the cross-sectional view as edges at 431, 432) follows the saddle shaped 3D curvature of the bone crest adjacent the anatomical socket, while the outer joint line of the interface between the transgingival interlock abutment 403 and the crown 405 (shown in the cross-sectional view as edges a 421, 422) follows the saddle shaped 3D curvature adjacent the gum line of the gingiva 435.

[0234] Again, this is not a standard curvature of a cylindrical mass-produced implant. To the contrary, this design is individually performed per specific tooth of a pre-identified patient. The shape data are derived from clinical images of the dental anatomy of such patient. In this specific context, the design takes into account the anatomical cross-section of the implant body 401 to at least substantially match the shape of the extraction/implantation socket 407, or at least substantially match the root of the tooth being extracted, and have its upper rim 437 (see FIG. 42) substantially match the 3D curvatures of the bone crest, and its orientation match the orientation of the original tooth (not shown) and/or as desired to correct errors in the orientation of the original tooth.

[0235] As perhaps best shown in FIG. 43, the apical extending rising 413 of the transgingival interlock abutment 403 can have projections 441-443, that tend to follow the structure of the root projections 445-447 (FIG. 42), respectively. The shape of the joint 411 can be determined using various mathematical expressions known to those of ordinary skill in the art such as, for example, a three-dimensional moving average of points along the outer surface of the root structure of the implant 401. The substantially parallel gap between the two adjacent surfaces 433, 434, that build the joints 411, 412, is, in the illustrated configuration, about 150 micrometers to accommodate a minimal thickness of the glass solder for the sub-gingival joint 411 and for the cement for the iso- or supra-gingival joint. The apical joint 411 is assembled and temporarily fixated by resin or cement based adhesives or a combination thereof, having a thickness (coatings plus adhesives) between 50 and 250, preferably of 150 micrometers. FIG. 44 illustrates the transgingival interlock abutment 403 landed within a recess 449 (see FIG. 42) having an inner surface shape which complements the apical extending rising 413 extending therein.

[0236] In preparation of the assembly of the apical joint, the joint facing surfaces of the zirconia part and of the titan part (medical grade titanium alloy or medical grade commercially pure titanium) are each furnace-fired with a silicatised coating. The parts are fused with a glass-soldering material at about between 750 and 850 degrees Celsius scale, preferably at 800. The furnace-fired joint materials having a cumulated thickness (coatings plus solder) between 50 and 250, preferably of 150 micrometers; while the silicate coating shows an approx. thickness of 50 micrometers per surface.

[0237] The joint/interface between the transgingival interlock abutment 403 and the crown 405 was discussed previously in the context of FIG. 19. In preparation of the assembly of the occlusal joint 412, according to the exemplary embodiment, the joint facing surfaces of the zirconia parts, are furnace-fired with a silicatised coating that is roughened by sandblasting and/or acid etching, using a silan-coupling agent as a primer. The thicknesses of the coatings cumulate to an approx. thickness of 50 micrometers per surface.

[0238] FIG. 45 shows an exploded view of the dental prosthesis 400 shown in FIG. 41. FIG. 46 shows an exploded view of a dental prosthesis 400 having an implant body 401, a transgingival interlock abutment 403, and in place of the crown 405, an integrated support device (described later) for providing primary stability to implant body-abutment assembly or a version of the dental prosthesis 400 employing a temporary crown 405 having a reduced size to accommodate engagement with integrated support device.

[0239] Note, according to the illustrated configurations, each transversal and lateral cross-section of the components of the dental prosthesis 400, 400, are custom-shaped, having an individual three-dimensional shape that is substantial asymmetric, that does not include generic concentric shapes, that does not include generic symmetric shapes, and that does not include convolutional shapes. The respective form-locking fit of the prosthetic interfaces forming the joints 411, 412 are clearly indicated for understanding by those skilled in the art. The outer circumferential edges traveling with the contour of the joints 411, 412 varies in the direction of a longitudinally axis of the implant body 401 and in transversal direction with respect to the distance to such longitudinal axis. For those skilled in the art, it is clearly indicated that the three-dimensional shapes of the aforementioned interface surfaces correlate with the outer surface of the crown/root, respectively, and with each other. Further, in a tooth such as an incisor, for example, the maximal transversal dimension of the implant body 401 adjacent the outer circumferential edge 437 (see, e.g., FIG. 42) is significantly bigger than the minimal transversal dimension of the implant body 401 adjacent the outer circumferential edge 437 (FIG. 42 as well).

[0240] Designing the Interlocking Compound Dental Implant

[0241] FIGS. 47-56 illustrate an example of a method of designing the interlocking compound one-piece dental prosthesis 400 (shown in FIGS. 40 & 41) formed of three primary pieces, based upon the three-dimensional virtual model 451 of at least portions of the non-functional natural tooth (best shown in FIG. 1 on the left hand side). According to an example of the three-piece dental prosthesis configuration, as perhaps best shown in FIG. 47, the step of forming a virtual model of a dental prosthesis 453 (FIG. 56) includes separating a portion of the three-dimensional virtual model 451 along the virtual bone-facing gum line representation 457 to form a modeled virtual root portion 459, and separating the remaining portion of the model at the outer gum line 461 to form a virtual midline portion 463 of the virtual model of the transgingival interlock abutment of the virtual model of the dental prosthesis 453 (FIG. 56) and to form the virtual crown portion model 465 modeling the outer surface of the physical crown, e.g., crown 405 (best shown in FIG. 41) or an outer surface portion of the integrated support device (described later) 405 (FIG. 46).

[0242] According to the illustrated embodiment shown in FIG. 47, the modeled virtual crown portion 465 models a crown having a full-size shape. As perhaps best shown in FIG. 48, if it is desired to manufacture a temporary crown such as, for example, one having a slight infra-occlusion designed to avoid occlusal contacts with an opponent tooth during the healing phase, the step of forming the virtual dental prosthesis 453 can also include copying the modeled virtual crown portion 465 to form a virtual crown component 467 and reducing the dimensions of at least portions of the virtual crown component 467 to form the outer surface of the virtual temporary crown 468.

[0243] If the goal is to model a dental prosthesis having a reduced-size (e.g., temporary) crown, according to the exemplary embodiment, the step of forming the virtual dental prosthesis 453 (FIG. 56) also includes copying at least portions of the virtual occlusally facing crown component 467 (or virtual crown portion 465) to form a virtual occlusally facing crown component 469. The step also includes reducing the dimensions of at least portions of the modeled virtual occlusally facing crown component 469; and in the exemplary configuration which provides enhanced structural stability, smoothing/adjusting the contours to form a virtual occlusal extending rising interface 471. The step can also include copying the virtual occlusal extending rising interface 471 to form a virtual apical facing crown component 473 and reducing the dimensions to form a virtual occlusal extending rising 475 modeling the occlusal extending rising 415 (see, e.g., FIG. 43) of the virtual transgingival interlock abutment 493 (FIG. 56).

[0244] If the goal is to model a dental prosthesis having full-size crown, as perhaps best shown in FIG. 49, according to the exemplary embodiment, the step of forming the virtual dental prosthesis 453 (FIG. 56) includes copying at least portions of the modeled virtual occlusally facing crown portion 465 to form the virtual occlusally facing crown component 467. Note, this embodiment, the virtual occlusally facing crown component 467 also models the physical crown surface. The step also includes copying at least portions of the modeled occlusally facing virtual crown portion 465 or virtual occlusally facing crown component 467 to form the virtual crown component 469. The step also includes reducing the dimensions of at least portions of the modeled virtual occlusally facing crown component 469; and in the exemplary configuration which provides enhanced structural stability, smoothing/adjusting the contours to form the virtual occlusal extending rising interface 471. The step also include copying the virtual occlusal extending rising interface 471 to form a virtual apical facing crown component 473 and reducing the dimensions to form the virtual occlusal extending rising 475 modeling the occlusal extending rising 415 (e.g., FIG. 43) of the virtual transgingival interlock abutment 493 (FIG. 56).

[0245] As perhaps best shown in FIG. 50, the step of forming the virtual dental prosthesis 453 (FIG. 56) includes the step of copying at least portions of the virtual midline portion 463 to form a virtual midline component 476, alternatively, dragging the virtual midline portion 463 to be used in constructing the virtual dental prosthesis 453, as will be described later. Note, the virtual midline portion 463 is an outward facing shell, most typically having a non-flat occlusally facing extension at virtual outer gum line 461 and a non-flat apically facing extension at the virtual bone-facing gum line representation 457. Both typically follow an individual saddle contour line of the occlusally facing edge at least partially matching the contour of the outer virtual gum line, and the apical facing edge at least partially matching the contour of the virtual bone crest line adjacent the extraction socket.

[0246] According to the illustrated embodiment shown in FIG. 47, the modeled virtual root portion 459 models a root of an existing non-functional tooth of the specific patient. As perhaps best shown in FIG. 51, if it is desired to manufacture an implant body having a larger size, such as, for example, to enhance osseointegration, or a smaller size to provide for additional coating layers or to enhance perio-type integration, the step of forming the virtual dental prosthesis 453 (FIG. 56) can also include copying the modeled virtual root portion 459 to form a virtual root component 477 and either reducing or enlarging the dimensions of at least portions of the virtual root component 477, as desired, to form an outer surface of a virtual implant body 478.

[0247] If the goal is to model a dental prosthesis having an implant body having a larger or smaller root design, according to the exemplary embodiment shown in FIG. 51, the step of forming the virtual dental prosthesis 453 (FIG. 56) includes the steps of copying at least portions of the virtual root component 477 (or virtual root portion 459) to form virtual root component 479. The step also includes reducing the dimensions of at least portions of the modeled virtual root component 479; and in the exemplary configuration which provides enhanced structural stability, smoothing the contours to form the virtual apical extending rising interface 481. The step can also include copying the virtual apical extending rising interface 481 to form a virtual occlusally facing root component 483 and reducing the dimensions to form the virtual apical extending rising 485 modeling the apical extending rising 413 (see, e.g., FIG. 43) of the virtual transgingival interlock abutment 493 (FIG. 56).

[0248] If the goal is to model a dental prosthesis having an implant body having a substantially matching root design, as perhaps best shown in FIG. 52, the step of forming the virtual dental prosthesis 453 (FIG. 56) includes the steps of copying at least portions of the modeled virtual root portion 459 to form the virtual root component 477. Note, this embodiment, the virtual root component 477 also models the physical root surface. The step also includes copying at least portions of the virtual root component 477 (or virtual root portion 459) to form a virtual root component 479. The step further includes reducing the dimensions of at least portions of the modeled virtual root component 479; and in the exemplary configuration which provides enhanced structural stability, smoothing the contours to form a virtual apical extending rising interface 481. The step also includes copying the virtual apical extending rising interface 481 to form a virtual occlusally facing root component 483 and reducing the dimensions to form a modeled virtual apical extending rising 485 modeling the apical extending rising 413 (see, e.g., FIG. 43) of the virtual transgingival interlock abutment 493 (FIG. 56).

[0249] Note, although the illustrations describe a root portion matching the root of a non-functional tooth, one of ordinary skill in the art would recognize that the modeled virtual root portion 459 can instead represent an alternative portion of the dental anatomy including the shape of the cavity to receive the physical implant body 401 of the dental prosthesis 400 (see, e.g., FIG. 41).

[0250] As shown in FIG. 53, the step also includes combining the modeled virtual crown component 467 or modeled virtual crown portion 465 (see, e.g., FIG. 47, for same-size modeling) or virtual crown component 468 (e.g., for reduced/enlarged size modeling) with the virtual apical facing crown component 473 to form a virtual crown model 491 of the virtual dental prosthesis model 453 (FIG. 56), e.g., modeling a physical crown 405 (see FIGS. 40-41). Note, the aforementioned reductions to derive the virtual occlusally facing crown component and the virtual apical facing crown component should be/need to be coordinated to guarantee a minimal numerical and subsequently minimal physical thickness of between approximately 0.3 mm to 0.7 mm (typically 0.4 mm) of the physical crown cap 405 (best shown in FIG. 45) for stability reasons.

[0251] As shown in FIG. 54, the step also includes combining the virtual occlusal extending rising 475, the virtual midline component 476 (or virtual midline portion 463), and the virtual apical extending rising 485 to form a transgingival interlock abutment model 493 of the virtual dental prosthesis model 453 (FIG. 56), e.g., modeling a physical abutment 403 (see FIGS. 40-41 and 43).

[0252] As shown in FIG. 55, the step also includes combining the virtual root component 477 or modeled virtual root portion 459 (see, e.g., FIG. 47, for same-size modeling) or virtual root (apical facing) component 478 (e.g., for reduced/enlarged size modeling) with the virtual occlusally facing root component 483 to form a virtual root component model 495 of the virtual dental prosthesis model 453 (FIG. 56), e.g., modeling a physical implant body 401 (see FIGS. 40-41 and 42). Note, the aforementioned reductions to derive the virtual occlusally facing root component and the virtual root component apical facing root component should be/need to be coordinated to guarantee a minimal numerical and subsequently a minimal physical thickness of between approximately 0.2 mm to 0.7 mm (typically 0.3 mm) of the physical implant body (best shown in FIG. 42) for stability reasons.

[0253] As shown in FIG. 56, the step also includes combining the virtual crown model 491, the transgingival interlock abutment model 493, and the root component model 495 to form the virtual dental prosthesis model 453, e.g., modeling a physical dental prosthesis 400 (see FIGS. 40, 41 and 45) or a physical dental prosthesis 400 (see FIG. 46).

[0254] Note, the dimensions of the virtual occlusal extending rising 475 is reduced to be smaller than the dimensions of the virtual apical facing crown component 473, and the dimensions of the virtual apical extending rising 485 is reduced to be smaller than the dimensions of the virtual occlusally facing root component 483. These dimensional reductions in the three-dimensional size of the pairs of surfaces that build an interface and/or form the form-locking fit are to account for manufacturing tolerances and to account for a certain thickness of the layer of adhesive, cement or glass solder, etc., generally in the range of 50 to 300 micrometers, but preferably approximately 100 micrometers. Further, the smoothing can be performed using various mathematical functions known to those of ordinary skill in the art to enhance structural stability at the component interfaces. Note, that all combinations of surface shells mentioned in the preceding paragraphs can include a design step of closing potential gaps while patching the surface components known to those of ordinary skill in the art to build numerically tight 3D surface objects used for further CAD/CAM processing.

[0255] Integrated Support Device

[0256] Component Description of the Integrated Support Device

[0257] According to various embodiments of the present invention, primary stability is favorably achieved by a custom made integrated support device that connects parts of a dental prosthesis with an adjacent tooth or teeth or other dental structures like existing implants, bridges and the like. The concept of a support device that is custom made in the laboratory in advance serves two purposes, the correct positioning of the prosthesis and the achievement of reasonable primary stability. After the dental implant is healed in, the integrated support device is to be clinically detached from the implants body (that may include an abutment portion) so that the implant body can receive a definite crown. In an embodiment of this invention, the definite crown is manufactured prior to the detachment of integrated support device, based on the design data of the dental prosthesis according to the exemplary embodiment of the present invention.

[0258] In an exemplary embodiment of the present invention, a dental prosthesis 500 is provided as depicted in FIG. 57. In the shown embodiment, and integrated support device 501 including a temporary crown portion body 503 and bonding wings 505 form one part, i.e., the crown portion body 503 entails wings 505 that attach to the adjacent teeth 507.

[0259] A cut away view of this prosthesis 500 is depicted in FIG. 58. In this view, it can be seen that the prosthesis 500 includes a one-part implant 509 (e.g., combined abutment and implant body) and a temporary crown portion body (cap) 503 forming one part with its wings 505 attaching to the adjacent teeth 507. The cap 503 can be attached to the one-part implant 509 with adhesive means such as cement. However, a partially adhesive silicone 513 can also be used for attaching the cap 503 to the one-part implant 509. This provides the advantage that micro-movements of the cap 503 and wings 505 (as one part) are damped. This reduces the micro-movements of the implant 509, and thereby enhances the integration of the implant 509 into the extraction socket.

[0260] FIGS. 59-66 illustrate another embodiment of an integrated support device 521, which can be applied in place of the crown 405 (see, e.g., FIG. 41) to stabilize and provide primary stability to the dental implant 401 and to maintain the abutment 403, and through that, the dental implant 401, at a user desired position and inclination when positioned within and being integrated into the jawbone cavity of the pre-identified patient. According to the illustrated example, the integrated support device 521 (see, e.g., FIGS. 59 and 60) includes a prosthesis interface member 523, e.g., in the form of a temporary crown, configured to engage and land atop and surround substantial portions of an occlusal extending rising 415 of an abutment 403 connected to a dental implant 401 of a dental prosthesis 400 (see, e.g., FIGS. 44 and 61-64 positioned within a jawbone cavity of a pre-identified patient. Alternatively, the prosthesis member 523 can be connected to rising 181 of FIG. 28, 199 of FIG. 29, 213 of FIG. 31, 217 of FIG. 32, 423 of FIG. 40; 101 of dental implant 91 (see FIGS. 19); or further alternatively, rising 117 of FIG. 20B, or indent 133 of FIG. 21, with modification. The integrated support device 521 also includes at least one, but more typically a pair of bonding wings 533 connected to or integral with the prosthesis interface member 523 and configured to bond to corresponding adjacent functional teeth (e.g., teeth 507, FIG. 65) when operably positioned thereon.

[0261] As perhaps best shown in FIGS. 65 and 66, according to the exemplary configuration, each of the bonding wings 533 includes a tooth-facing outer surface portion 535 adapted to adhesively bond to an outer surface portion 537 of a crown 539 of the adjacent functional tooth 507. Beneficially, through an at least substantially rigid/semi-rigid connection of the prosthesis interface member 523 to an adjacent tooth or the adjacent teeth 507 (FIG. 65) via the respective bonding wing or wings 533 (see, e.g., FIGS. 59 and 66) and as best shown in the explosion view of FIG. 61 the at least substantially rigid/semirigid connection to the occlusal extending rising 415, the integrated support device 521 functions to at least substantially rigidly fixate the prosthesis interface member 521 to stabilize and provide primary stability to the dental implant 401 during the healing period and to maintain the assembly including the abutment 403 and the dental implant 401 at a user desired position and inclination.

[0262] According to the exemplary configuration, the user desired position and inclination reflects a geometrical relation to the one or more adjacent functional teeth 507 located adjacent the jawbone cavity and the dental implant 401 (see FIG. 64), determined via imaging data as understood by those of ordinary skill in the art. Additionally, according to such configuration, the outline of a cross-section of the crown portion 540 (FIG. 65) of the prosthesis interface member 523 correlates to an outline of a corresponding cross-section of the occlusal extending rising/portion 415 of the dental prosthesis 531 (shown in FIGS. 62 and 63). According to the exemplary configuration, the crown portion 540 of the prosthesis interface member 523 is custom manufactured for the specific pre-identified patient receiving the dental prosthesis 531. This can beneficially provide a higher quality custom device and/or provide for manufacturing a set or kit of devices including both temporary and permanent crown portions and the necessary primary support structure device or devices, ready for application with minimum effort on the part of the dental practitioner.

[0263] As perhaps best shown in FIG. 66, according to an exemplary configuration, in order to enhance the connection to the occlusal extending rising/portion 415 of the dental prosthesis 531 (see, e.g., FIG. 61), the prosthesis interface member 523 includes an occlusal extending recess 541 extending substantially into a body of the prosthesis interface member 523 to define a complementing interface surface 543. Beneficially, the occlusal facing surface 545 of the occlusal extending rising 415 and the complementing interface surface 543 of the prosthesis interface member 523 together create a form-lock fit when the occlusal facing surface 545 of the occlusal extending rising/portion 415 is operably positioned within the occlusal extending recess 541. According to the illustrated configuration, the occlusal facing recess 541 extending into the body of the prosthesis interface member 523 has an asymmetrical custom three-dimensional surface shape substantially directly correlated with an asymmetrical custom three-dimensional surface shape of the occlusal extending rising/portion 415 of the abutment 403. According to the illustrated configuration, the complementing interface surface 543 can also include a substantial asymmetric apical-facing indent 547 extending into the recess 541 (FIG. 66), which reflects, for example, a direct correlation with the surface shape of a medial section of the crown portion 540 (FIG. 65) of the prosthesis interface member 523.

[0264] As perhaps best shown in FIGS. 65 and 66, in order to improve positioning and/or to provide for manual positioning without the necessity for custom application tools, and to reduce the amount of structure of the bonding wings 533 extending lingually, as noted above, the bonding wings 533 can have a custom three-dimensional surface shape dimensioned to substantially match a three-dimensional shape of the outer surface portion 537 of the crown 539 of the adjacent functional tooth/teeth 507. The custom three-dimensional surface shape can beneficially be provided, for example, at the manufacturing facility prior to insertion of the dental implant 401 into the jawbone, and thus, prior to application of bonding material to the tooth-facing outer surface portion 535, and prior to bonding attachment of the tooth-facing outer surface portion 535 to the outer surface portion 537 of the crown 539 of the respective adjacent functional tooth 507, determined, for example, using imaging data. The imaging data can be obtained through various methodologies understood by those of ordinary skill in the art.

[0265] As shown in FIGS. 65-70, beneficially, the bonding wings 533 can be dimensioned to be sufficiently small so as to not extend atop the portion of an occlusal surface 551 (FIG. 65) of the respective adjacent functional tooth or teeth 507 that is normally aligned to contact an occlusal surface 552 (FIG. 67) of a corresponding opposite-facing functional tooth 507 (when the respective tooth is a posterior tooth). That is, in order to improve alignment positioning, portions 555 of the bonding wings 533 (see, e.g., FIGS. 65-66 and 68-70) can extend atop portions of the adjacent functional teeth 507 with a low enough profile and in natural fissures or gaps so that they are not engaged by opposite facing teeth 507 when the jaws of the patient are in a normal closed position (see, e.g., FIGS. 68-70). Note, as perhaps best shown in FIG. 71, the bonding wings 533 of the integrated support device 521 are correspondingly also dimensioned so as to not extend atop a portion of an incisal surface 561 of a respective adjacent functional tooth 507 that would be normally aligned to contact a surface of a corresponding opposite-facing functional tooth (not shown) when the respective tooth is an anterior tooth.

[0266] Additionally, according to an exemplary configuration, the prosthesis interface member 523 provides a temporary crown portion 540 (FIG. 72), e.g., having an infra-occlusion to thereby avoid occlusal contacts with an opponent tooth when operably positioned.

[0267] Designing the Integrated Support Device

[0268] According to a preferred configuration, manufacturing of the integrated support device 521 is performed using various computer controlled machines and/or rapid prototyping as would be understood by those of ordinary skill in the art. Accordingly, to provide a truly custom integrated support device 521, a virtual model is first developed which can be utilized to provide the necessary data to control the various machines.

[0269] As shown in FIG. 73, the step of forming a virtual model 553 (FIG. 77) of an integrated support device 521 such as that shown, for example, in FIG. 66 includes separating a portion of the three-dimensional virtual model 451 along the outer gum line 461 to form a virtual crown portion model 465 modeling the outer surface of the physical prosthesis interface member 523 (FIG. 66).

[0270] According to the illustrated embodiment, the modeled outer surface 568 of the virtual prosthesis interface member 591 (see, e.g., FIG. 75) models a prosthesis interface member 523 having a full-size crown portion (see, e.g., FIG. 65). If it is desired to manufacture a crown portion having a slight infra-occlusion designed to avoid occlusal contacts with an opponent tooth during the healing phase (see, e.g., FIG. 72), the step of forming the virtual integrated support device model 553 (FIG. 77) can also include copying the modeled virtual crown portion 465 to form an outer surface model 567 of the virtual prosthesis interface member 591 and reducing the dimensions of at least portions of the outer surface model 567 of the virtual prosthesis interface member 591 (FIG. 75) to form the infra-occlusal outer surface model 568 of the virtual prosthesis interface member 591.

[0271] As noted above, if the goal is to model a virtual prosthesis interface member outer surface 568 having a crown portion of reduced (or enlarged) size, according to the exemplary embodiment, the step of forming the virtual integrated support device model 553 also includes copying at least portions of the outer surface model 567 of the virtual prosthesis interface member 591 (or virtual crown portion 465 or outer surface model 568) and reducing the dimensions of at least portions of the respective model; and in the exemplary configuration which provides enhanced structural stability, smoothing/adjusting the contours to form a virtual occlusal extending rising interface model 571.

[0272] If the goal is to model a dental prosthesis having full-size crown, as perhaps best shown in FIGS. 74 and 75, according to the exemplary embodiment, the step of forming the virtual integrated support device model 553 (FIG. 77) includes copying at least portions of the modeled virtual crown portion 465 to form the virtual outer surface model 567 of the virtual prosthesis interface member 591. The step also includes copying at least portions of the modeled virtual crown portion 465 or outer surface model 567 of the virtual prosthesis interface member 591 and reducing the dimensions of at least portions of the respective model; and in the exemplary configuration which provides enhanced structural stability, performing the step of smoothing/adjusting the contours to form the virtual occlusal extending rising interface model 571.

[0273] As shown in FIG. 75, the step also includes combining the modeled outer surface model 567 of the virtual prosthesis interface member 591 or modeled virtual crown portion 465 (e.g., for same-size modeling) or outer surface model 568 (e.g., for reduced/enlarged size modeling) with the virtual occlusal extending rising interface 571 to form a virtual prosthesis interface member 591 of the virtual dental prosthesis model 453 (FIG. 56), e.g., modeling a physical crown 405 (see FIGS. 40-41).

[0274] As shown in FIG. 76, forming a virtual bonding wing model 592 modeling a bonding wing 533 having a tooth-facing surface configured to bond to a corresponding adjacent functional tooth and combining the prosthesis interface member landing surface of the virtual bonding wing model 592 with the corresponding surface of the virtual prosthesis interface member 591 to form the interim model 593. The virtual bonding wing model 592 can be produced by slicing a skin portion of a model of the adjacent functional teeth 507 (FIG. 65) and the non-functional tooth, if available. Note, the skin portions can be defined and virtually combined by free-form surfaces (e.g. stitched together) in the virtual domain with a surface modeling CAD software (e.g. Geomagic STUDIO 11) running on a computer.

[0275] As shown in FIG. 77, the step also includes combining the virtual bonding wing model portion of interim model 593 with a duplicate copy 595 of the virtual bonding wing model 592 to provide a desired thickness to the bonding wing model portion to form the virtual integrated support device model 553, e.g., modeling a physical integrated support device 521 (see FIGS. 59-60 and 65). Note, the thickness of the virtual bonding wing model 592 can be uniformly defined, but also non-uniformly distributed, so that, for example, the wings portions of the models are designed to have a reasonable stability to thereby provide primary stability when the physical integrated support device 521 is fabricated with respect to the virtual integrated support device model 553 and assembled with the transgingival interlock abutment 403 (FIG. 64) and the implant body 401 (FIG. 64) and bonded to the corresponding adjacent functional teeth (e.g., teeth 507, FIG. 65) when operably positioned thereon. The thickness of a substantial part of each wing portion of the virtual bonding wing model 592 should be in a range of between approximately 0.3 mm and 2 mm, preferably approximately 0.8 mm, while the middle portion can be, for example, infinitesimal small or not existent as long as each of the aforementioned wing portions of the virtual bonding wing model 592 intersect or otherwise virtually connect with a substantial thickness to the virtual prosthesis interface member 591, when virtually combined or superposed to the physical integrated support device 521.

[0276] Note, that all combinations of partial surface shells described in this specification can include a design step of closing potential gaps between adjacent shell portions while patching the surface components, as such design step is understood by those of ordinary skill in the art to build numerically definite 3D surface objects i.e. virtual models of physical parts used for further CAD/CAM processing. Note also, that any and all virtual partial models described in this specification can be combined (e.g. merged by Boolean 3D combination or stitched together) in the virtual domain, and/or simply superposed when displayed, and/or considered in addition to each other when considered in subsequent computer aided manufacturing (CAD) process when actually fabricating the physical parts from or at least responsive to the combined model or the superposed or otherwise additionally considered partial models. As known to those of ordinary skill in the art, however, it is sufficient when the models have adjacent, identical surfaces or surfaces that intersect (or any combination thereof) in order to be combined or superposed in the virtual domain or when considered in addition to each other when actually fabricating the physical parts that represents the merged model or the superposed or adjacently considered partial models.

[0277] Customized Tooth-Conforming Splint

[0278] According to various embodiments of the present invention, primary stability is favorably achieved by a custom made splint that connects parts of a dental prosthesis with an adjacent tooth or teeth or other dental structures like existing implants, bridges and the like. The concept of a splint that is custom made in the laboratory in advance serves two purposes, the correct positioning of the prosthesis and the achievement of reasonable primary stability.

[0279] FIGS. 78A-78B illustrate a single-tooth prosthesis 601, having a manufactured crown portion and a manufactured root portion. The shape of each is derived, for example, from in-vivo imaging data prior to the extraction of the tooth to be replaced. By extraction of said tooth to be replaced, the extraction void 603 was created. The adjacent teeth (mesial and distal of the extraction socket) are healthy natural teeth 605. The extraction was indicated, for example, due to a serious porosity of the root of the extracted tooth. The extraction socket was partially curetted by the doctor of record, removing damaged soft tissue. Antibiotic tablets are given orally to the patient in advance to suppress the inflammation and to avoid additional infection as a result of the clinical trauma of removing the tooth. The crown and the root shape are derived from the imaging data. In addition, the crown shape of the adjacent teeth 605 and a desired position and inclination of the prosthesis are derived from the imaging data. Based on all this data a custom-shaped splint 607 is designed and fabricated. The splint is used to position and orient the prosthesis 601 in the dental structure 609 building the extraction void in geometrical relation to the adjacent teeth 605. Being held in the desired position and orientation, the custom-shaped splint 607 is connected with adhesive means to the prosthesis 601 and the adjacent teeth 605. For example, light curing adhesives are used in that context. Alternatively, dual curing (light and chemical curing after mixing two components) adhesives can be used. In an exemplary clinical process, a moist-tolerant resin enforced cement (e.g. GC Fuji ORTHO SC) is used.

[0280] Finally, the prosthesis 601 is fixated in its desired position and the crown portion, is thereby integrated into the occlusion and articulation of the patients dental anatomy. Slight corrections performed by the doctor of record with a high-speed rotating instrument may be necessary to optimize the occlusal contact points. The prosthesis can be immediately loaded by the patient for the day-to-day use of mastication, since the splint distributes the functional load from the dental prosthesis 601 to the adjacent teeth 605. With that, the custom splint connected to a prosthesis and adjacent teeth or other dental structures provides the primary stability while either the perio-type integration or the osseointegration takes place.

[0281] According to various embodiments of the present invention, and each of the methods described above, the dental prosthesis 601 (FIGS. 78A and 78B), or respectively the dental prosthesis 602 (FIG. 79), can have a three-dimensional surface shape matching, or at least substantially matching, that of the side-crown portion of the tooth to be replaced. Correspondingly, the portions of the splint 607 shaped to connect to the dental prosthesis 601/602 can have a complementary three-dimensional surface shape matching, or at least substantially matching the surface shape of the corresponding side-crown portion of the dental prosthesis. Additionally, the one or both portions of the splint 607 shaped to connect to the adjacent tooth or teeth 605, respectively, can have a complementary three-dimensional surface shape matching, or at least substantially matching that of the side crown portion of the respective adjacent tooth or teeth 605.

[0282] According to an embodiment of the invention, the splint 607 can also have an extension that covers, for example, not only the lingual crown portions of the prosthesis and of the adjacent teeth 605, but includes also incisal edges in the event anterior teeth are affected or cusps in the event posterior teeth are affected, preferably shaped in such a manner that the extension does not to interfere with the occlusion of the upper and lower dentition of the patient receiving the appliance when inserted. In a further embodiment, the extension is shaped in such a manner that significant occlusal surfaces of the teeth of interest can also be covered by the splint. According to an embodiment of configuration, the extension does not, however, extend beyond the occlusal or incisal surfaces to engage the buccal or labial surface (for lingual-positioned splints). In an exemplary embodiment, the design and the fabrication of the splint 607 may include such contours covering additional surfaces or portions thereof to enable better positioning of the prosthesis, with such contours to be physically removed after bonding in the patient's mouth by the doctor of record.

[0283] In the context of the aforementioned custom splint, FIG. 79 shows, for example, the process steps of fabricating a prosthesis 602 and such a splint 607. A partial silicone impression is taken from the mouth of the patient representing the dental (occlusal) crown anatomy in the neighborhood where a prosthesis will be integrated (step S). The silicone impression can include, for example, not only the crown and gingival situation of the jaw of interest, but also the occlusal situation of the corresponding crowns of the opponent jaw (see, e.g., 507 and 552 of FIG. 67). It is also possible that the situation is defined by more than one silicone impression, impressions made from other materials than silicone (e.g. alginate), or that the impressions include a wax bite that defines the upper to lower jaw relationship. The impression is (or the impressions are) scanned and three-dimensional STL data of the shape are derived representing the crown geometry of the tooth to be extracted, the crown geometry of the adjacent teeth (and, in an exemplary embodiment, of the opponent teeth), and the geometrical relation between those crown data (step T). Additionally, the patient's dental anatomy is imaged with a computed tomography device (step C). Computed tomography (CT) is a medical imaging method employing tomography where digital geometry processing is used to generate a three-dimensional volumetric image of the internals of an object that can be displayed as a large series of layered two-dimensional grey scale X-ray images. The layered grey scale X-ray data in digitized format is then computer analyzed and three-dimensional STL data are derived representing the dental anatomy of the patient (step Q). All aforementioned STL data can be scaled, merged and/or combined (step D) to generate accurate three-dimensional shape data from tooth to be replaced and the adjacent (and opposing) dental anatomy (step E). Boolean algorithms can be used to generate combined data of high-quality. In a first design of the prosthesis, its position and orientation within the adjacent (and opposing) dental anatomy, especially in relation to the crown portions of the adjacent teeth, and a second design of a custom shaped splint that includes shape portions of the crown of the prosthesis and of the crowns of the adjacent teeth, are derived. The first and the second design may be modified and optimized (step F). This can be done automatically or interactively by having a technician operating the respective computer equipment. Computer numerical control data (CNC), for example, in IGES format for computer aided manufacturing (CAD) devices are derived from the final three-dimensional design data (step H). Usually rapid prototyping equipment is having the aforementioned step already integrated. The prosthesis is fabricated in response to the IGES data, for example, by a CAM high-speed 5-axis milling/grinding machine (step I and J). Additionally, the rapid prototyping machine, such as, for example, a layer-by-layer wax printing machine, is fabricating a three-dimensional wax representation (sample) from the three-dimensional design data (step U). The sample is prepared and embedded for lost wax investment casting, whereby the wax sample is burned out and the investment mould is filled with liquid precious metal (e.g., dental gold alloy; step V). After cooling down to room temperature, the embedding material is removed, the runner is cut-off and the splint is polished and surface prepped for bonding (step W). It should be noted that while FIG. 79 contemplates possibly interaction with an operator, one skilled in the art would readily appreciate that certain steps are combined, further differentiated, and that this functionality may be partially or fully automated. The aforementioned CAD/CAM machining and the rapid prototyping are exemplary embodiments. It would also be possible to employ CAD/CAM machining to fabricate the splint and/or to use rapid prototyping to fabricate the dental prosthesis; or if the dental prosthesis is designed as an assembly of parts or components, any combination thereof.

[0284] In yet another embodiment, a prosthesis 602 is segmented and such segments are fabricated using different manufacturing technologies. FIG. 80 shows the process steps of receiving design data of a prosthesis 602 in STL format (step E), separating portions in a computer aided design (CAD) process (step X and Y), deriving computer numerical control (CNC) data and utilizing computer aided manufacturing (CAM) machinery, for example, high-speed milling/grinding machines (step I) to fabricate the respective portions (step Z and AA) in response to the CNC data. Note, in step I and Z a mould is manufactured, for example, substantially inverse, with or without a shrinking factor, to the shape shown in step X. The separated portions used to make the prosthesis 602 (step BB). This can be performed by molding a crown portion substantially representing the shape definition shown in step X atop of the part shown in step AA by means of the mould shown in step Z .

[0285] In another embodiment of the fabrication process of a prosthesis 602 together with a splint 607, shown in FIG. 81, in a first step (SSSSS) a physical impression of the denture of the patient is taken, e.g., with silicon material. In a further step (TTTTT), the crown geometry of the patient's crowns are obtained from the patient's dental anatomy and translated to three-dimensional STL-data. Additionally, the patient's dental anatomy is imaged with a computed tomography device (CCCCC). The layered grey scale X-ray data in digitized form (QQQQQ) are analyzed, three-dimensional STL-data (DDDDD) are derived representing the anatomy of the patient's denture. Note, there are other numerical formats available to describe the surface data of a three-dimensional virtual object or model, so that whenever in this specification a STL data format is referenced, it should be read as 3D surface data, for example in STL format. The grey scale X-ray (QQQQQ) data can be represented in the format of the DICOM standard (DICOM: Digital Imaging and Communications in Medicine). In a further step (EEEEE), Boolean algorithms are used to generate combined data of high quality of a virtual prosthesis. The data of the virtual prosthesis are optimized (FFFFF), e.g., automatically or interactively by a technician operating the respective computer equipment. From the data of the virtual prosthesis, computer numerical control (CNC) instructions are derived. These are CNC-instructions of two kinds. Firstly, CNC-instruction are derived for fabricating the dental prosthesis in a CAM (Computer-added Manufacturing) high-speed milling/grinding machine (IIIII and JJJJJ). Moreover, CNC-instructions (UUUUU) are derived for fabricating a splint in step (VVVVV and WWWWW) that individually fits to the corresponding prosthesis.

[0286] In a further embodiment of the aforementioned fabrication process, the two steps SSSSS and TTTTT can be combined to one step. Therefore, a three-dimensional camera can be used as known from the CEREC three-dimensional camera systems provided by the Sirona Group to avoid the process (SSSSS) taking a physical impression of the dental anatomy of interest. As in the fabrication process depicted in FIG. 81, a computed tomography device is used for imaging the dental anatomy of the patient's tooth to be replaced and its adjacent teeth.

[0287] From the surface data, the CNC-instructions can also be derived for a chair side fabrication device. Such a chair side fabrication device for dental prostheses is known from the inLab MC XL milling unit which is offered by the Sirona Group. Therewith, in an exemplary embodiment of the present invention, the prosthesis and the corresponding splint can be fabricated at the dentist's site. Firstly, this is a simplification of the overall fabrication and delivery process. Especially, for dentists that have their own milling unit for fabricating crowns etc., the chair side production enhances the overall treatment process and saves time, e.g., in cases where fast replicas are needed by a patient.

[0288] In another embodiment, the custom splint is fabricated in an indirect method for example, by lost-wax investment casting. FIG. 82 shows the process steps of fabricating a custom splint (e.g., splint 607) from design data, and fabricating a model of the splint by rapid prototyping, building a mould around the splint, burning out the model and casting the splint by investment casting. As shown in the figure, the process starts with receiving the 3D design data of a custom splint (step CC), then a sample part of the custom splint is fabricated using stereo-lithography conforming to the design data (step DD). The sample part is embedded (step EE) in, for example, a gypsum-bound investment material (like Cera Fina, Whip Mix, U.S.A.). The investment mould is heated and the material of the sample part is burnt out (step FF). The mould filled by vacuum or centrifugal casting with liquid precious alloy (for example, Argenco 42 Type IV extra hard, The Argon Corporation, U.S.A.step GG), and the embedding mass is removed (step HH). The casting runner is cut from the custom splint (step II), and the custom split is polished and prepared for bonding (step JJ). It should be noted that while process contemplates possible interaction with an operator, one skilled in the art would readily appreciate that certain steps can be combined, or further differentiated, and that this functionality may be partially or fully automated. Alternatively to the precious metal, the investment casting can be done with stainless steel or other suitable non-precious dental alloy known to those skilled in the art. In yet another embodiment, the custom splint is perforated or prepared with retention features on the bonding surface (like a mesh) for better light curing capabilities and better bonding strength. Note, the individual process steps disclosed in FIGS. 79 to 82 can be employed to fabricate other components of the dental prosthesis. For example, the process steps shown in FIG. 82 can be employed to fabricate either one or more of the parts 521, 403 and 401 shown in FIG. 61, or, for example, the process steps shown in FIG. 81 can be modified to combine the virtual prosthesis design with the virtual splint design and to segment this combination in multiple parts, to make in step 11111 and JJJJJ the parts 403 and 401 shown in FIG. 61, while step UUUUU and WWWWW can be modified to make part 521 shown in FIG. 61.

[0289] In another embodiment, the clinical process of integrating the prosthesis 601/602 is performed as shown in FIG. 83. The process begins by preparing the extraction socket for insertion, which may include rinsing (step KK), micro-etching (sandblasting) and/or etch (e.g., phosphoric acid) bonding the surface of prosthesis (step LL), micro-etching (sandblasting) and/or etch (e.g., phosphoric acid) bonding surface of the adjacent teeth or other dental structures (step MM). Once the extraction socket is prepared, the prosthesis is inserted (step NN), applying light curing adhesive to all bonding surfaces (step 00). The prosthesis is then positioned and oriented in the desired geometrical relation to the adjacent teeth or other dental anatomy of interest using the custom splint as a positioning aid or guide (step PP). The prosthesis and the splint are held firmly in position while the adhesive is light cured with a dental UV-light curing device (step QQ) in order to fixate the prosthesis in its desired position. Excess adhesive is removed (step RR), and a final check and adjustif necessaryof the occlusion and articulation of the patient in respect to the contact situation of the prosthesis to the teeth or other dental structures of the opponent arch is performed (step SS).

[0290] In a further enhancement of the present invention shown in FIG. 84, the attachable splint 611 provides a number of recesses 613 formed as holes. Other methods of perforation may be used. This enhancement of the attachable splint 611 can be useful for the adhesive material, e.g., glue, which attaches the splint to the prosthesis 602 and the adjacent teeth 605. An adhesive that needs to attach to a smooth splint surface may not provide enough stability since no hold points are provided for the adhesive to attach to. The holes through the splint enhance the adhesive in attaching to the splint. The adhesive material can propagate into the holes or the perforations and, after having changed into solid state, provide additional mounting means between splint and prosthesis or adjacent teeth respectively.

[0291] Another embodiment of the present invention is depicted in FIG. 85. Therein, the splint 621 is designed in a way that it is attached to the dental prosthesis 602 and to one of the adjacent teeth 605. Such a splint design can be useful in cases where the other adjacent tooth 605 on the opposite side of the prosthesis 602 is not qualified for the attachment of a wing of the splint 607.

[0292] Another embodiment of the present invention is depicted in FIG. 86. This embodiment is characterized by a splint 631 which is not only attached to the prosthesis 602 and the adjacent teeth 605 but also to the next teeth 605 adjacent to the adjacent teeth 605 of the dental prosthesis 602. Such an embodiment of the splint 607 can be useful when the two directly adjacent teeth 605 are not qualified for providing primary stability to the prosthesis 602 via the splint. The enhanced splint 631, therefore, makes use of the stability of the next teeth 605 adjacent to the adjacent teeth 605. Any combination of the foregoing is possible to reflect limitations of the dental anatomy of interest, attaching the prosthesis to one or more adjacent teeth, on one or either side of the prosthesis.

[0293] FIG. 87 illustrates a custom-shaped splint 641 attached to the customized dental prosthesis 602 and the two adjacent teeth 605. The design and fabrication of such a splint 641 is based on the imaging data of, for example, the extracted tooth. The splint 641 is used to position and orient the prosthesis 602 in the dental structure 609 building the extraction void 643 in geometrical relation to the adjacent teeth 605. Similar to the splint 607 shown in FIG. 78, the splint 641 is connected with adhesive means to the prosthesis 602 and the adjacent teeth 605. In contrast to the splint 607, the splint 641 is designed in a way that it provides elasticity in vertical direction 645. This elasticity is achieved by an elastic or spring-type connection 647. Beneficially, the prosthesis 602 can immediately be used in the day-to-day use of mastication in which forces are applied to the adjacent teeth 605 and transmitted over the elastic/spring-type connection 647 to the dental prosthesis 602. Thereby, a certain level of micro-movement is applied to the dental prosthesis 602. This movement can serve to enhance the process of either perio-type or osseointegration.

[0294] FIG. 88 illustrates a customized detachable splint assembly 650 (including a bridge portion 651 and prosthesis attachment 653) adapted to be aligned to be attached to the customized dental prosthesis 602 and the two adjacent teeth 605. In an exemplary configuration, the attachment portion 653 shown connected to the dental prosthesis 602 is pre-assembled together with the dental prosthesis 602 by adhesive means. In an alternative embodiment, the attachment portion is an integral part of a temporary crown adhesively connected to an abutment portion and a root portion of the dental prosthesis. Thereby, the dental prosthesis 602 with the attachment portion 653 can be adjusted during the implantation procedure and correctly positioned in the alveole 655. When the dental prosthesis 602 is correctly positioned in the alveole 655 and between the surrounding adjacent teeth 605, the bridge portion 651 is attached to the attachment 653 and to the adjacent teeth through its flanks 657. This is achieved by sliding the bridge portion 651 sideways in a way that the elliptic cut 659 surrounds the elliptic attachment portion 660. The elliptic attachment portion 660 has an outer surface size and shape matching an inner surface size and shape of the elliptic cut 659. The attachment portion 653 provides two recesses 661 that proceed vertically downwards from the upper ends 663 of the elliptic attachment portion 660, vertically downwards. The bridge portion 651 contains two holes 665 that proceed from the upper ends 667 vertically downwards. After the bridge portion 651 is attached to the attachment portion 653, two pins 671 are pressed into the holes 665, thereby, firmly connecting and fixing the attachment portion 653 to the bridge portion 651. Note, the elliptic shape is provided by way of example. Additional shapes are within the scope of the present invention.

[0295] FIG. 89 shows the detachable splint assembly 650 viewed along the 89-89 line in FIG. 88 from a plan view in a pre-assembly conditioni.e., the bridge portion 651 is unattached to the prosthesis attachment portion 653. The figure further illustrates the step of aligning the elliptic cut 659 of the bridge portion 651 with the elliptic attachment portion 660 of prosthesis attachment 653 for connection thereto. In FIG. 90, the bridge portion 651 is firmly attached to the prosthesis attachment portion 653. With elliptical attachment portion 660 inserted through the elliptical cut 659, the two pins 671 (see also FIG. 88) are pressed into the holes 665.

[0296] In another embodiment, the bridge portion 651 is attached to the two adjacent teeth 605 after extraction of the non-functional tooth of interest to serve as a positioning guide placed prior to the insertion of the assembly of prosthesis attachment portion 653 and the dental prosthesis 602 (or respectively the combined part including the prosthesis attachment portion 653 and the dental prosthesis 602) in the alveole 655. The undersized shape of the dental prosthesis 602 compared to the shape of the alveole 655 allows the user/clinician to first decline the assembly (or combined part) and pass the elliptic attachment portion 660 of prosthesis attachment 653 by the bridge portion 651. Second, due to the design, the user/clinician can incline the assembly (or combined part) towards the bridge portion 651 in order to insert the elliptical attachment portion 660 into the elliptical cut 659. Third, due to the design, the user/clinician can press the two pins 671 (see also FIG. 88) into the holes 665 to define the final position and orientation of the dental prosthesis 602 with respect to the alveole 655 and to provide primary stability by affixing the prosthesis attachment portion 653 and subsequently the dental prosthesis 602 to the two adjacent teeth 605.

[0297] In another exemplary embodiment, two prosthesis attachment portions (in analogy to 653) are directly bonded onto the two adjacent teeth 605, while the bridge portion 651 includes in addition to the elliptical cut 659 two further elliptical cuts (in analogy to 659) to receive the two aforementioned prosthesis attachment portions that are directly bonded onto the two adjacent teeth. With that, the two prosthesis attachment portions intended to be directly bonded onto the two adjacent teeth 605 can be adhesively bonded onto the two adjacent teeth 605 prior to the extraction of the non-functional tooth of interest, using the bridge portion 651 as a positioning guide. Then, the non-functional tooth of interest is extracted, and the assembly of prosthesis attachment portion 653 and the dental prosthesis 602 (or respectively the combined part including the prosthesis attachment portion 653 and the dental prosthesis 602) can be placed into the alveole 655. Finally, the bridge portion 651 is inserted so that the three elliptic attachment portions (one shown as 660 and to be made in analogy and bonded to the adjacent teeth) attach with the three elliptical cuts (one shown as 659 and two to be made in analogy to 659) of the bridge portion 651, so that when each such elliptical connection is secured with two pins 671, the final position and orientation of the dental prosthesis 602 with respect to the alveole 655 is achieved and the primary stability is provided.

[0298] In another exemplary configuration, the bridge portion 651 is pre-assembled (or combined) with the prosthesis attachment portion 653, which is pre-assembled (or combined) with the dental prosthesis 602, and the assembly (or the combined part) is inserted and affixed to the two prosthesis attachment portions being previously directly bonded onto the two adjacent teeth 605 as described before. A separate placement guide, similar to the single bride portion, can be used to place and adhesively bond the two prosthesis attachment portions onto the two adjacent teeth 605 prior to the extraction of the non-functional tooth of interest.

[0299] Note, according to various embodiments of the present invention, all specific embodiments discussed with the aforementioned various design features of the splint (e.g. 607, FIGS. 78A and 78B, 611 FIG. 84, 631, FIG. 86, 641, FIG. 87, 651, FIGS. 88, 89 and 90) can be applied as they are applicable to design of the various embodiments of the integrated support device (e.g. 501, FIGS. 57 and 58, 521, FIGS. 59 to 66, 71, 72 and 77, 521, FIG. 71, 593, FIG. 76) and vice versa.

[0300] Miscellaneous

[0301] One of ordinary skill in the art will recognize that various aspects of the inventions as explained above can readily be combined with each other.

[0302] The meaning of CAD shall include but shall not be limited to any and all technology of computer aided design.

[0303] The meaning of CAM shall include but shall not be limited to any and all technology of computer aided manufacturing.

[0304] The meaning of CNC shall include but shall not be limited to any and all technology of computer numerical control as it relates to manufacturing machinery and systems, including but not limited to rapid prototyping devices and systems.

[0305] The meaning of rapid prototyping shall include but shall not be limited to all technologies qualified for manufacturing of copies of virtual three-dimensional objects and also technologies qualified for mass customization or the mass production of copies of customized or adapted geometries to the needs of an individual patient. Rapid prototyping in this context shall include but not be limited to manufacturing technologies based on the digital data, by a process that includes depositing material, in accordance with the digital data, layer-by-layer in a plurality of layers each constituting a two-dimensional cross section of a solid object having an edge defined by data of the three-dimensional surface, the layers being stacked in a third dimension to form the solid object having a three-dimensional surface defined by the data. All such rapid prototyping technologies can be used directly to manufacture the part of interest, for example, by selective laser sintering or indirectly by fabricating first, e.g., a resin or wax sample of the part of interest and second using for example, lost-wax casing to duplicate such sample and fabricate therewith the part of interest. It also includes sintering techniques where the green body is printed in response to computerized numerical controlled (CNC) data and then sintered to its final material properties. Sintering in this context includes pressure and heat.

[0306] The meaning of rapid prototyping shall be used in its broadest technical sense, where individualized parts are made from virtual representations, and shall include respective additive, subtractive and forming technologies used to three-dimensionally shape work pieces. The meaning of additive shaping shall include but shall not be limited to selective laser melting, selective laser sintering, stereo-lithography, 3-D printing or depositing of wax, wax-bound powders, adhesive-bound powders, slurries. The meaning of subtractive shaping shall include but shall not be limited to 3D laser shaping, CNC-grinding, CNC-turning, and CNC-milling technologies, and other machining and finishing technologies. The meaning of shape forming shall include but shall not be limited to near net-shape forming technologies, CNC-stamping, and CNC-pressing and casting technologies.

[0307] The meaning of body of an artificial tooth shall include but shall not be limited to the part of the prosthesis representing a root structure for perio-type or or osseointegration or the combined part of the prosthesis representing a root structure for perio-type or osseointegration and a support structure for a crown or a bridge.

[0308] The meaning of prosthesis shall include any substantially artificially shaped part of any natural and artificial material. In this sense a dental prosthesis for perio-type integration would have to be distinguished to any human tooth used for intentional re-implantation.

[0309] Whenever the context requires, the word prosthesis shall be deemed to include the word implant and vice versa.

[0310] 3D shall mean three-dimensional.

[0311] The meaning of CT shall include but shall not be limited to any and all technology of computed tomography.

[0312] CBCT shall mean cone beam computed tomography and shall include DVT technology.

[0313] DVT shall mean digital volume tomography.

[0314] Three-dimensional X-ray image shall include but shall not be limited to voxel data, volumetric X-ray data, at least two two-dimensional X-ray images in DICOM format, a stack of two-dimensional X-ray images, data received from CBCT or other CT, MRT, ultrasonic and TOF devices, or any combination thereof

[0315] The meaning of MRT shall include but shall not be limited to any and all technology of magnetic resonance tomography.

[0316] The meaning of TOF shall include but shall not be limited to any and all technology employing Time-of-Flight procedures.

[0317] The meaning of imaging and scanning shall include but shall not be limited to any and all technology of acquiring two-dimensional and/or three-dimensional data of physical objects or parts of a human body.

[0318] The meaning of clinical imaging data shall include but shall not be limited to in-vivo and in-vitro processes that result in any anatomical data of the anatomy of a human being. In this context the term data shall include but shall not be limited to two-dimensional and three-dimensional data.

[0319] The meaning of three-dimensional data shall include but shall not be limited to surface (e.g., triangulated data) and volumetric (e.g., voxel) data.

[0320] The meaning of perio-type tissue and periodontal tissue shall include but shall not be limited to any soft tissue surrounding a tooth.

[0321] The meaning of perio-type ligature, perio-type ligament periodontal ligature, ligament or periodontal ligament shall include but shall not be limited to the fibrous connective tissue interface usually located between a human tooth and the anatomical structure of the jaw of a human being.

[0322] The meaning of each one of the following: perio-type integration, parodontal integration, integration into the periodont, integration into the parodont, integration into the dental soft-tissue, integration into the dental ligament and alike word constructions shall include but shall not be limited to the integration into the periodontal or perio-type ligament structure or other perio-type tissue or any other biological structure of the human dental anatomy except osseointegration. In this sense the term perio-type integration shall include but shall not be limited to the integration of a prosthesis to be adopted and held by periodontal and/or perio-type ligament tissue of a human being.

[0323] In this sense a prostheses for periodontal integration would have to be distinguished to any osseointegrated implant.

[0324] The meaning of cavity shall include but shall not be limited to the periodontal cavity, a cavity of the jaw bone structure, a cavity of the alveolus or a combination thereof

[0325] The meaning of extraction socket shall include prepared or unprepared extraction sockets. The meaning of prepared shall include but shall not be limited to being surgically pared, abraded, scraped or curetted by mechanical instruments or laser technology based devices.

[0326] The meaning of replacement, to replace, to be replaced shall include but shall not be limited to any substitution, where one object fills the former position of another object. In the context of the foregoing such substitution can be performed at any time, so that for example, the term replacement shall not be limited to a replacement in a timely manner.

[0327] The meaning of a manufactured one-piece object shall not be limited to homogeneous objects, and shall include but shall not be limited to manufactured assemblies, objects that are coated, objects that are consisting of more than one pieces or materials bonded together or any combination thereof

[0328] The meaning of a clinical one-step process or a clinical one-step method shall include but shall not be limited to a series clinical process or method steps performed in one or more clinical events as long as no further iteration is required that includes clinical process or method steps and process or method steps that cannot be performed chair-side.

[0329] The meaning of immediate load of an implant shall include but shall not be limited to any all integration concepts of implants where the occlusal portion of the implant (e.g., the crown portion facing the opponent jaw) is not protected against the alternate load of mastication by additional protective means.

[0330] The meaning of configured to be integrated into the existing occlusion of the patients dentition shall include but shall not be limited to any shaping of a crown or a crown-like portion of a prosthesis that contacts or otherwise substantially fills the gap between adjacent crowns, and any shaping that contacts or otherwise substantially interacts with the opponent crowns of the dentition in the process of masticating food.

[0331] In dentistry, the term occlusion is used to refer to the manner in which the teeth from upper and lower arches come together when the mouth is closed. The meaning of occlusion shall mean but shall not be limited to the manner the teeth of the upper or lower arch are fitting and coming in contact with each other while the mouth is closed or during chewing (articulation). It shall also include the fit and contact of adjacent teeth within one arch. The meaning of integrated into the occlusion shall include but shall not be limited to the configuration and integration of the fit and contact situation of a prosthesis within the existing or new build occlusion within the same and the opponent arch.

[0332] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus, if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself

[0333] The various embodiments and aspects of embodiments of the invention disclosed herein are to be understood not only in the order and context specifically described in this specification, but to include any order and any combination thereof. Whenever the context requires, all words used in the singular number shall be deemed to include the plural and vice versa. Words which import one gender shall be applied to any gender wherever appropriate. Whenever the context requires, all options that are listed with the word and shall be deemed to include the world or and vice versa, and any combination thereof. The titles of the sections of this specification and the sectioning of the text in separated paragraphs are for convenience of reference only and are not to be considered in construing this specification.

[0334] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalent within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

[0335] In the drawings and specification, there have been disclosed embodiments of the invention, and although specific terms are employed, the terms are used in a descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. It must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention. It will be apparent to those skilled in the art that alterations, other embodiments, improvements, details and uses can be made consistent with the letter and spirit of the disclosure herein and within the scope of this disclosure patent, which is limited only by the following claims, construed in accordance with the patent law, including the doctrine of equivalents. For example, the various enhancements to the splint embodiments such as the spring-type connection, among others, along with the manufacturing methodologies, are applicable to the various embodiments of the integrated support structure, and vice versa. Also for example, the various enhancements of the integrated support structure embodiments of, along with the manufacturing methodologies, are applicable to the various embodiments of the dental implant assembly/dental prosthesis described herein.

[0336] This patent application is a non-provisional continuation application of U.S. patent application Ser. No. 13/767,999, filed on Feb. 15, 2013, which itself is non-provisional application of and claims priority to and the benefit of U.S. Provisional Patent Application No. 61/602,470, filed on Feb. 23, 2012, and U.S. Provisional Patent Application No. 61/454,450, filed Mar. 18, 2011, and U.S. patent application Ser. No. 13/767,999 is a continuation-in-part of U.S. patent application Ser. No. 13/247,843, filed Sep. 28, 2011, and U.S. patent application Ser. No. 13/247,607, filed Sep. 28, 2011, where both continuation-in-part applications claim priority to and the benefit of U.S. Provisional Patent Application No. 61/454,450 filed on Mar. 18, 2011, U.S. patent application Ser. No. 12/763,001, filed Apr. 19, 2010, now U.S. Pat. No. 8,602,780, U.S. patent application Ser. No. 11/724,261, filed Mar. 15, 2007, now U.S. Pat. No. 7,708,557, and U.S. patent application Ser. No. 11/549,782 filed on Oct. 16, 2006, now U.S. Pat. No. 8,454,362, each incorporated by reference in their entirety.

[0337] In the claims which follow, reference characters if used to designate claim steps are provided for convenience of description only, and are not intended to imply any particular order for performing the steps.