METHOD FOR PRODUCING A DENTURE BASE SEMI-FINISHED PRODUCT

Abstract

The invention relates to a method for producing a denture base semi-finished product with the following steps:

1) Recording and digitalizing the oral cavity situation of a patient, wherein a digital three-dimensional oral cavity model of the patient is produced, or providing a digital three-dimensional oral cavity model of the oral cavity situation of a patient;

2) Implementing a first calculation in which a digital three-dimensional first model (A) of a denture base is calculated, wherein the oral cavity model of the oral cavity situation is used as a basis for the first calculation;

3) Conducting a second calculation, in which a digital three-dimensional second model (B) of a denture base semi-finished product is calculated from the first model (A) of the denture base, wherein volume is added at least in sections to the three-dimensional model (A) of the denture base; and

4) Producing the denture base semi-finished product with a Rapid Prototyping method, wherein with the Rapid Prototyping method, a CAM method is used and the digital three-dimensional second model (B) of the denture semi-finished product is used as the basis for the CAM method.

The invention also relates to a device for implementing such a method and a denture base semi-finished product produced using such a method.

Claims

1. A method for producing a denture base semi-finished product with the following steps: 1) Recording and digitalizing an oral cavity situation of a patient, wherein a digital three-dimensional oral cavity model of the patient is produced, or providing a digital three-dimensional oral cavity model of the oral cavity situation of a patient; 2) Implementing a first calculation in which a digital three-dimensional first model of a denture base is calculated, wherein the oral cavity model of the oral cavity situation is used as a basis for the first calculation; 3) Conducting a second calculation, in which a digital three-dimensional second model of a denture base semi-finished product is calculated from the first model of the denture base, wherein volume is added at least in sections to the three-dimensional model of the denture base; and 4) Producing the denture base semi-finished product with a Rapid Prototyping method, wherein with the Rapid Prototyping method, a CAM method is used and the digital three-dimensional second model of the denture semi-finished product is used as the basis for the CAM method.

2. The method according to claim 1, comprising, when conducting the first calculation of the first model of the denture base, using further data as a basis for calculation.

3. The method according to claim 1, comprising, during the production of the denture base semi-finished product, using a Rapid Prototyping method in which the denture base semi-finished product is produced with a degree of precision of 100 m to 8 mm.

4. The method according to claim 1, comprising, during production of the denture base semi-finished product, using an additive Rapid Prototyping method.

5. The method according to claim 1, comprising, during the production of the denture base semi-finished product, using a method selected from the group consisting of: Fused Layer Modeling/Manufacturing (FLM) of plastics or waxes, Fused Deposition Modeling (FDM) of plastics or waxes, Laminated Object Modeling (LOM) of plastic films, Layer Laminated Manufacturing (LLM) of plastic films, Electron Beam Melting (EBM) of plastics or waxes, Multi Jet Modeling (MJM) of waxes or plastics, polyamide casting of polyamides, Selective Laser Melting (SLM) of plastics, Selective Laser Sintering (SLS) of plastics or waxes, 3-D-Printing (3DP) of plastic granulate or plastic powder, Space Puzzle Molding (SPM) of plastics or waxes, Stereo Lithography (STL or SLA) of plastics or waxes, and Digital Light Processing (DLP) of photopolymerizable fluid plastics.

6. The method according to claim 1, wherein the denture base semi-finished product is made of a plastic or wax.

7. The method according to claim 1, comprising, with the second calculation for calculating the digital three-dimensional second model of the denture base semi-finished product, adding, at least in sections, a distance vector to the first model of the denture base, wherein the distance vector is oriented vertically to the surface of the first model and the value of the distance vector is selected between 100% and 200% to be as large as the degree of precision of the Rapid Prototyping method used.

8. The method according to claim 1, comprising, when calculating the second model of the denture base semi-finished product, including a mark on the surface of the model in the calculation which is applicable or is used for positioning and aligning the completed denture base semi-finished product.

9. The method according to claim 1, comprising, when calculating the second model of the denture base semi-finished product, adding volume at least on a palate plate and/or contact surface onto the dental arches of the model of the denture base.

10. A method for producing a denture base comprising a method for producing a denture base semi-finished product according to claim 1, comprising, following production of the denture base semi-finished product, producing the denture base from the denture base semi-finished product using a subtractive CAM method based on the first model of the denture base.

11. The method according to claim 10, comprising using a subtractive milling method as a subtractive CAM method.

12. A computer-controlled device for implementing a method according to claim 1, comprising an installation for producing the denture base semi-finished product with a Rapid Prototyping method, and comprising a computer system which comprises a module for implementing the calculations of the method and a module for controlling the installation for producing the denture base semi-finished product.

13. A denture base semi-finished product produced using a method according to claim 1.

14. A denture base produced using a method according to claim 10.

15. The method according to claim 2, wherein the further data relates to occlusion, position, and alignment of the prosthetic teeth to be inserted, the position of a marking for aligning the denture base to be produced, data which has been obtained with the aid of a jaw template including occlusal guides, and/or data which is normally recorded on the patient to set an articulator.

16. The method according to claim 3, wherein the degree of precision is 100 m to 1 mm.

17. The method according to claim 3, wherein the degree of precision is 500 m to 1 mm.

18. The method according to claim 4, comprising, during production of the denture base semi-finished product, using a 3D printing method.

19. The method according to claim 5, comprising, during the production of the denture base semi-finished product, using a method selected from the group consisting of: Fused Deposition Modeling (FDM) of acrylonitrile butadiene styrene or polylactide, Multi Jet Modeling (MJM) of thermoplasts or UV-sensitive photopolymers, Selective Laser Sintering (SLS) of thermoplastsStereo Lithography (STL or SLA) of fluid resin, duromer, or elastomer, and Digital Light Processing (DLP) of photopolymerizable fluid plastics.

20. The method according to claim 19, comprising, during the production of the denture base semi-finished product, using a method selected from the group consisting of: Selective Laser Sintering (SLS) of polycarbonates, polyamides, or polyvinyl chloride thermoplasts, Digital Light Processing (DLP) of photopolymerizable fluid plastics, and Stereo Lithography (STL or SLA) of a fluid resin, duromer or elastomer.

21. The method according claim 6, wherein the denture base semi-finished product is made of a pink or gum-colored plastic.

22. The method according claim 21, wherein the pink or gum-colored plastic is a polymethyl methacrylate (PMMA).

23. The method according to claim 7, comprising, with the second calculation for calculating the digital three-dimensional second model of the denture base semi-finished product, adding, on all sides or on each surface of the first model, the distance vector to the first model of the denture base.

24. The method according to claim 7, wherein the value of the distance vector is selected between 100% and 150% to be as large as the degree of precision of the Rapid Prototyping method used.

25. A method for producing a denture base comprising a method for producing a denture base semi-finished product according to claim 10, comprising, following production of the denture base semi-finished product, producing the denture base by milling.

26. The method according to claim 11, wherein with the subtractive milling method, a degree of precision is achieved which is greater than the degree of precision of the Rapid Prototyping method.

27. The method according to claim 26, wherein a degree of precision of at least 50 m is achieved.

28. The method according to claim 26, wherein a degree of precision of at least 10 m is achieved.

29. A computer-controlled device for implementing a method according to claim 12, wherein the installation for producing the denture base semi-finished product with a Rapid Prototyping method is a 3D printer.

Description

[0057] Exemplary embodiments of the invention will now be described below with reference to one schematically represented FIGURE, although without restricting the invention, in which:

[0058] FIG. 1 shows an overview of the method steps according to the invention for producing a denture base 10, with which a method according to the invention for producing a denture base semi-finished product 6 is used.

[0059] In a first step, a three-dimensional image of the oral cavity of a patient 1 is recorded with an intra-oral scanner 2. The oral cavity is at least partially toothless. The intra-oral scanner 2 can be a suitable stereo camera, for example. The image data of the intra-oral scanner 2 is transferred to a computer 4 which calculates from the image information a three-dimensional digital oral cavity model of the relevant part of the oral cavity for the production of the denture.

[0060] On the basis of the oral cavity model and, if necessary of further data, such as data on the occlusion, position and alignment of the dentures to be inserted, the position of a marking for aligning the denture base to be produced, data which has been gained with the aid of a jaw template, including occlusal guides and/or data which is normally recorded on the patient in order to set an articulator, the computer 4 calculates a three-dimensional digital first model A of a denture base which fits the oral cavity situation and if necessary further parameters (such as the occlusion). The model A is shown in a broken line in FIG. 1 in order to make it clear that this is a virtual model A of the denture base, which only exists and is stored as a data quantity in the computer 4. The model A of the denture base contains no dentures, which are only added later, the position, alignment and form of which have however already been taken into account in the calculation of the first model A of the denture base. The model A of the denture base can therefore already contain recesses, indentations and/or contact surfaces, for example, for holding and/or connecting dentures.

[0061] As a next step, a digital three-dimensional second model B of the denture base semi-finished product is calculated using the computer 4 from the digital three-dimensional first model A of the denture base. For this purpose, volume is added on all surfaces of the first model 2 of the denture base. The model B is also shown in a broken line in FIG. 1 in order to make it clear that this is a virtual model B of the denture base semi-finished product, which only exists and/or is stored as a data quantity in the computer 4. The first model A of the denture base can thus be fully incorporated by the second model B of the denture base semi-finished product. In particular, volume is added on the underside of the model A of the denture base, which forms the contact surface for the toothless jaw col and/or the gum (shown in FIG. 1 below).

[0062] Based on the second model B of the denture semi-finished product, with the aid of the computer 4 and/or controlled by the computer 4, a real denture base semi-finished product 6 is produced from a plastic or a wax with the aid of a 3D printer 8 or another installation 8 for implementing a Rapid Prototyping method. The plastic has the pink color of gums. The denture base semi-finished product 6 thus produced is then tensioned into a 5-axis or 4-axis mill 12 or another device for implementing a subtractive and highly precise CAM method, and on the basis of the first model A of the denture base, a real denture base 10 is milled out of the denture base semi-finished product 6. The 5-axis or 4-axis mill 12 operates considerably more precisely, but also more slowly, than the 3D printer 8. While therefore the rough form is produced as a denture base semi-finished product 6 with the fast but imprecise 3D printer, the subsequent precision work is conducted using the 5-axis or 4-axis mill 12. The 5-axis or 4-axis mill 12 is also controlled by the computer 4 or by another control unit (not shown) on the basis of the first model A of the denture base.

[0063] Due to the fact that the second model B of the denture base semi-finished product is produced on the basis of the first model A of the denture base or on the basis of data which is also decisive for producing the first model A of the denture base, the use of material can be minimized, as can the time needed for producing the denture base in the 5-axis or 4-axis mill 12. As a result, the consumption of plastic or wax and the wear of the milling head of the 5-axis or 4-axis mill is reduced and the method is accelerated.

[0064] The features of the invention disclosed in the above description, and in the claims, FIGURES and exemplary embodiments, can be essential both individually and in any combination required for the realization of the invention in its different embodiments.

LIST OF REFERENCE NUMERALS

[0065] 1 Patient

[0066] 2 3D intra-oral scanner

[0067] 4 Computer

[0068] 6 Denture base semi-finished product

[0069] 8 3D printer/installation for implementing a Rapid Prototyping method

[0070] 10 Denture base

[0071] 12 CAM-controlled 5-axis or 4-axis mill

[0072] A Model of the denture base

[0073] B Model of the denture base semi-finished product