SYSTEM AND PROCESS FOR DUPLICATION OF DENTURES

Abstract

Systems and processes for the duplication of dentures from existing dentures. The interior and exterior of the dentures are scanned and a best fit procedure is used to create a fully digitized denture. The denture teeth are selected from a library that is the closest fit to the original denture teeth. The library teeth are offset a preset distance to compensate for the best fit. The teeth are then subtracted from the digitized denture. The margins of the denture are then cleaned after subtracting the teeth. The denture base is then ready for manufacturing. The teeth are then installed onto the denture base and provided to the patient.

Claims

1. A system for creating a duplicate denture from an existing denture, the system comprising: a processing device configured to execute computer-readable code; a memory device connected to said processing device for storing computer-readable code; an interface for receiving data relevant to a particular patient and storing said data in said memory device; a rendering engine for creating a digital three dimensional model of the existing dentures from scans of the existing image; a selection engine for selecting the denture teeth that best fits the digital denture model; a manipulation engine adding a preset amount to the denture teeth, for subtracting the denture teeth from the denture model and for cleaning the margins of the denture model.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a diagram of the work flow process of one preferred embodiment.

[0014] FIG. 2 is an illustration of a denture to be duplicated.

[0015] FIG. 3 is an illustration of the scanned images of the denture.

[0016] FIG. 4 is an illustration of a digital three dimensional model of the denture.

[0017] FIG. 5 is another view of the digital model of the denture.

[0018] FIG. 6 is an illustration of the digital denture model.

[0019] FIG. 7 is an illustration of the model with an offset added to the teeth.

[0020] FIG. 8 is an illustration of the digital denture with the teeth being subtracted.

[0021] FIG. 9 is an illustration of the digital denture base being cleaned after the teeth has been subtracted.

[0022] FIG. 10 is an illustration of the machined denture base.

[0023] FIG. 11 is another view of the machined denture base.

[0024] FIG. 12 is a view of the duplicated denture.

[0025] FIG. 13 is another view of the duplicated denture.

DETAILED DESCRIPTION

[0026] The present invention provides systems and process for the duplication of dentures. Descriptive embodiments are provided before for explanatory purposes. It is to be expressly understood that the present invention is not be limited to these descriptive embodiments. Other embodiments are considered to be within the scope of the present invention, including without limitation the use of the present invention for other applications, such as denture duplication, dental implants, and other dental and orthodontic applications. The descriptions below discuss the systems of the present invention as used in dental labs, but it is to be expressly understood that these systems could also be implemented in the dentist office or through a network allowing interaction between the dentist and the dental lab through the systems. The processes and systems of the present invention may also be used in combination with all or parts of the following applications, entitled System and Processes for Optimization for Dentures, Ser. No. 12/939,141; System and Process for Forming Anatomical Features in Dentures, Ser. No. 12/939,138; Combination Tool for Anatomical Measurement for Denture Manufacture, Ser. No. 13/249,210; and Removable Handle for Use with Dentures, Ser. No. 12/939,143 all of which are hereby incorporated herein by reference.

[0027] The terms denture base generally refers to the part of a denture that fits the oral mucosa of the basal seat, restores the normal contours of the soft tissues of the edentulous or partly edentures mouth, and supports the artificial teeth. The term denture refers to the denture base with the artificial teeth attached.

[0028] Overview

[0029] A preferred embodiment of the present invention provides systems and processes for duplicating a denture from an existing denture. The denture is scanned and a best fit procedure is used to create a fully digitized denture. An offset is added to the overall dimension of the denture teeth. The denture teeth with the offset are then subtracted from the digitized denture model. The margins of the denture are then cleaned after subtracting the teeth. The denture base is then ready for manufacturing. The teeth are then installed onto the denture base.

[0030] Process

[0031] A preferred embodiment of the present invention is disclosed that allows new dentures to be created from an existing denture. The patient provides their existing dentures to the dentist for scanning. Digital scans 30, 32 are created from the inside and outside of the original denture 20 as shown in FIGS. 2 and 3. Once the scans are performed, the denture can be returned to the patient. The system, as shown in the work flow diagram of FIG. 1, applies a series of routines to create a digital three dimensional model 40 of the existing denture as shown in FIGS. 4 and 5.

[0032] This digitized denture model 40 is then digitally compared with denture teeth from a library to select the best fitting denture teeth 50 in the scanned model as shown in FIG. 6. The denture teeth 50 are then offset by a preset amount as shown in FIG. 7. This adds an overall thickness to the teeth. The teeth are then digitally subtracted from the digitized denture model as shown in FIG. 8. The offset added to the teeth creates slightly larger pockets in the denture base. The margins are then cleaned after the teeth have been subtracted as shown in FIG. 9. This creates a digital model 60 of the denture base for the patient as shown in FIG. 10.

[0033] The denture teeth may be either selected from a library or fabricated from the digital model in a number of process. In this preferred embodiment, the denture base is machined in acrylic based on the digital model 60. This can be done relatively quickly. Once the denture base 70 has been fabricated as shown in FIGS. 10 and 11, the teeth 72 are installed and delivered to the patient for try-in and use as shown in FIGS. 12 and 13.

[0034] This entire process can be done in a relatively fast time frame. In some instance, the duplication process can take place in the dentist offices. In other instances, the scanned images of the existing denture can be transmitted to a nearby dental lab where the denture is fabricated and courier to the dentist.

[0035] In an alternative embodiment of the present invention, the interior and exterior of the dentures can be scanned as discussed above. The dentist can also provide additional information regarding the dentures and the patient as well. For example, the dentist may notice that the dentures are no longer properly fitting due to wear of the denture base or the teeth or due to changes in the patient's anatomy. This additional information may be used to change the digitized model of the denture.

[0036] In yet another alternative embodiment of the present invention, the dentist may provide additional information beyond the scanned images of the interior and exterior of the dentures. The dentist may use those existing dentures as an impression tray to take bite impressions of the patient. Those bite impressions are then scanned and used along with the scanned images of the interior and exterior of the dentures to create the digitized denture.

[0037] The occlusal scheme of the existing denture is maintained in the duplicate denture. The duplicate denture can be modified to accommodate anatomical, aesthetic and functional changes that might be necessary.

[0038] The digitized denture model 40, in another preferred embodiment, may also be used to create a model for a denture base. The teeth are subtracted from the model, and a denture base is directly fabricated from the denture base information. A denture base is then fabricated, the margins are cleaned and teeth are temporarily installed. This try-in denture is then tried onto the patient. If the fit is not correct, then the denture is used as a secondary impression tray to create a set of bite impressions. These impressions are scanned and used to select or fabricate another denture base. The teeth are installed again and the denture is tried on the patient. This process is repeated until the patient is satisfied. At that point, the teeth are permanently installed, the denture is finally processed and installed to the patient.

[0039] A preferred embodiment of the present invention may be implemented in a number of ways.

[0040] The above descriptions are intended for explanatory purposes and are not meant to the limit the scope of the claimed inventions. Other embodiments may be covered under the claims as well.