SYSTEM AND METHOD FOR MANUFACTURING OF DENTAL CROWNS AND CROWN COMPONENTS

Abstract

A method of manufacturing custom crown coping and infrastructures is provided. A metal portion (base) of an abutment is located in a model of a patient's mouth and the model is scanned. The data from the scan is then utilized to manufacture the ceramic portion of the abutment and the coping. In one embodiment, the coping and infrastructure is designed by first determining the shape and orientation of the final crown, subtracting a thickness for the crown from the shape to determine the shape and orientation of a coping, and subtracting a thickness for the coping to form the shape and orientation of an abutment.

Claims

1. A method of creating digital job information for at least one component of a dental restoration to be manufactured selected from the group consisting of a crown, multi-tooth unit, bridge, coping, crown coping, core, abutment and infrastructure, the method comprising the steps of: obtaining information regarding a physical indication of a patient's mouth; determining an outer shape of a dental restoration based on the physical indication of the patient's mouth; determining a manufacturing parameter for a component of the dental restoration to be manufactured based upon the determined shape of the dental restoration; wherein the determined manufacturing parameter is selected from a plurality of determined parameter options; and creating the digital job information based upon the determined manufacturing parameter.

2. The method as claimed in claim 1 wherein the determined parameter options include a variety of material options from which the component is designed to be manufactured.

3. The method as claimed in claim 2 wherein the material options include a material shape, size, configuration and/or consistency.

4. The method as claimed in claim 1 wherein the determined parameter options include a variety of manufacturing methods.

5. The method as claimed in claim 4 wherein one of the variety of manufacturing methods includes utilizing multiple manipulations at one time simultaneously.

6. The method as claimed in claim 5 wherein the step of utilizing multiple manipulations comprises utilizing multiple tools.

7. The method as claimed in claim 6 wherein at least one of the tools comprises a cutting tool.

8. The method as claimed in claim 4 wherein one of the variety of manufacturing methods includes utilizing multiple manipulations contemporaneously.

9. The method as claimed in claim 8 wherein the utilizing multiple manipulations comprises utilizing multiple tools.

10. The method as claimed in claim 9 wherein at least one of the tools comprises a cutting tool.

11. The method as claimed in claim 4 wherein one of the variety of manufacturing methods includes utilizing one of a plurality of machines.

12. The method as claimed in claim 1 wherein the determining step comprises organizing a material and a manufacturing method.

13. A method of creating digital job information for manufacturing a custom component of a dental restoration, the method comprising the steps of: obtaining information regarding a physical indication of a patient's mouth including data regarding a transfer medium and data regarding the conditions in the patient's mouth proximate to the restoration under development; utilizing the obtained information together with stored information regarding the transfer medium to design a component of a dental restoration; and creating the digital job information comprising the transfer medium and component design information for use in manufacturing the custom component.

14. The method as claimed in claim 13 said transfer medium provides data regarding hidden conditions in the patient's mouth.

15. The method as claimed in claim 13 wherein said transfer medium provides data regarding observable conditions in the patient's mouth

16. A custom component of a dental restoration manufactured by the steps of: obtaining information regarding a physical indication of a patient's mouth including data regarding a transfer medium and data regarding the conditions in the patient's mouth proximate to the restoration under development; utilizing the obtained information together with stored information regarding the transfer medium to design a custom component of a dental restoration; and creating digital job information comprising the transfer medium and component design information for use in manufacturing the custom component; and manufacturing the custom component using the digital job information.

17. A method of creating digital job information for manufacturing a dental restoration, the method comprising the steps of: obtaining information regarding a physical indication of a patient's mouth including data regarding transfer medium and data regarding the conditions in the patient's mouth proximate to the restoration under development; utilizing the obtained information together with stored information regarding the transfer medium to design one or more pieces for a dental restoration; and creating the digital job information comprising the transfer medium and restoration design information for use in manufacturing the restoration.

18. A computer implemented system for designing a dental restoration comprising: an input for receiving information regarding a physical indication of a patient's mouth including data regarding a transfer medium and data regarding the conditions in the patient's mouth proximate to the restoration under development; a tool for utilizing the obtained information together with stored information regarding the transfer medium to create digital job information comprising the transfer medium and restoration design information for use in manufacturing the restoration; wherein said restoration design information is determined to purposefully optimize the restoration.

19. A method of creating digital job information for manufacturing a dental restoration, the method comprising the steps of: obtaining information regarding a physical indication of a patient's mouth including data regarding the conditions in the patient's mouth proximate to the restoration under development; utilizing the obtained information together with stored information regarding an adaptable framework for holding raw materials during manufacturing of the restoration to design one or more pieces for a dental restoration; and creating the digital job information comprising the adaptable framework and restoration design information for use in manufacturing the restoration.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A preferred embodiment of the invention, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

[0016] FIG. 1 is a schematic of a method of manufacturing custom crown copings and infrastructures of the prior art.

[0017] FIG. 2 is a schematic of the method of manufacturing custom crown copings and infrastructures of the instant invention.

[0018] FIGS. 2a and 2b are partial front views of a master model implant analog of an embodiment of the instant invention.

[0019] FIG. 3 shows front and top views of an implant base portion.

[0020] FIG. 4 shows a core of an embodiment of the instant invention designed within the master model implant analog of FIGS. 2a and 2b.

[0021] FIG. 5 shows the core of FIG. 4 and a coping designed to fit over the core.

[0022] FIGS. 6a and 6b show a DCS frame of an embodiment of the instant invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0023] As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0024] Referring to FIG. 1 a schematic of a method of manufacturing custom crown copings and infrastructures of the prior art is shown. As is shown in FIG. 1, the manufacturing method of the prior art begins with the purchase of a two piece abutment from a manufacturer. The abutment is located in a model of the patient's mouth and the ceramic portion of the abutment is then modified by a technician to a shape that is appropriate for the location and orientation in the patient's mount. Once the ceramic portion of the abutment is modified to its final shape, the abutment, which is located in the model, is scanned. The data from the scan about the shape and orientation of the abutment, as well as the existing teeth surrounding the position of the abutment, is then used to manufacture a crown coping.

[0025] Referring to FIG. 2 is a schematic of the method of manufacturing custom crown copings and infrastructures of the instant invention. As is shown in FIG. 2, the manufacturing method of the instant invention begins with the purchase of the metal portion of the abutment from a manufacturer. The abutment is located in a model of the patient's mouth and the metal portion of the abutment, which is located in the model, is scanned. The data from the scan is then utilized to manufacture the ceramic portion of the abutment and the coping.

[0026] As is shown in FIGS. 2a and 2b, when a patient requires a tooth replacement, a three-dimensional model 10 of the patient's mouth is prepared. Using the model of the patient's mouth, a lab technician will fit the metal portion 20 of the abutment into the appropriate location 30 in the model. The model will then be scanned. The scan provides data about the orientation of the metal insert within the model of the mouth and also data about the existing teeth surrounding the position of the abutment. The data from the scan, along with stored data about the standard shape of the metal insert to which the ceramic portion is to be mounted, is used to determine and design the appropriate shape for the ceramic portion of the abutment. At the same time, the shape of the coping is internally designed, using the data so that the coping will fit over the designed ceramic portion of the abutment.

[0027] Referring to FIGS. 2a, 2b, 3, 4 and 5, the process of manufacturing a custom crown core and custom crown coping from a factory sintered block is shown. In the embodiment shown, the custom crown core and custom crown coping is made for use with an off-the-shelf lower abutment portion, such as the lower metal portion (Ti-base) of the Camlog Implant System. Information regarding the size and shape (X) of the off-the-shelf pieces are stored in a data file or library accessed by a milling machine (such as a DCS milling machine). For example, as is shown in FIG. 3, information regarding size and shape X for five diameters of implants is shown. The Ti-base 20 is placed in a master model implant analog 10 and the model is scanned to obtain data about the orientation of the base within the model (such as the 3-dimensional axis) and data about the existing teeth surrounding the position of the base within the model (such as the interdental/arch Y information). The data from the scan, Y, is combined with the stored size and shape information regarding the Ti-base, X, to design a custom crown core part 40 to fit over the Ti-base 20 and a custom crown coping 50 to fit over the custom crown core. The custom crown core will be designed to have predetermined minimum dimensions 42 (stored in library) based upon the size and shape of the Ti-base being used. In most instances however, the actual custom crown core will have dimensions greater than the library-stored minimum, thus the dimensions of the custom crown core 40 will include a wax-up 44 from the minimum dimensions 42. Once the final dimensions for the custom crown core 40 and the custom crown coping 50 are determined by wax-up software, the core and coping pieces are milled from a block of material.

[0028] In an alternative embodiment, rather than milling core 40 and coping 50 from a single block of material, the core and coping may be milled out of separate pieces of material. Referring to FIGS. 6a and 6b, one such embodiment is shown and described, in which the material for the core 40 is retained within a frame 100 for support during milling. Frame 100 is designed for use in a single axis milling machine, such as a DCS milling machine, to accomplish milling of custom crown cores. Frame 100 includes a molded/milled polymer base 110 which holds a threaded base 120 to which a blank 40a for the custom crown core 40 is attached. The frame is placed within the milling machine, and one of three angled blanks is chosen by control software of the machine depending upon the desired shape of the custom crown core 40 that is to be machined. This allows for undercutting of the blank which may be necessary for custom crown cores that will be located at a variety of angled orientations. Implants having a generally orthogonal orientation will generally utilize the 0 degree blank, 40a.sub.0, for milling. As the orientation angle increases to about 10 decrees from an orthogonal orientation, the 10 decree blank, 40a.sub.10, will be utilized. As the orientation angle increases to about 20 degrees from an orthogonal orientation, the 20 decree blank, 40a.sub.20, will be utilized. Because additional material is needed to provide the minimum dimension of the custom core in angled orientations, the diameters of the blanks increase as the angle increases (i.e. 10 degree blank is larger diameter than 0 degree blank, and 20 degree blank is larger diameter than 10 degree blank). Once custom crown core 40 milled, the design file is utilized to mill the coping from a separate block of material.

[0029] Once crown core 40 and coping 50 are milled, whether from a single piece of material, or from separate pieces, core 40 and coping 50 are hand finished.

[0030] In prior art systems, the custom dental crown coping and infrastructure (abutment) are manufactured from the ground up. The abutment is designed first and the coping is designed to fit the abutment. In the instant invention the custom dental crown coping and infrastructure can be manufactured from the ground up by first determining the shape and orientation of the abutment and then determining the shape and orientation of the coping.

[0031] Alternatively, the custom dental crown coping and infrastructure of the instant invention can be manufactured from the end product. In such a manner, the model is scanned and the shape and orientation of the final crown is determined or visualized. The thickness for the crown is subtracted to determine the shape and orientation of the coping. The thickness of the coping is then subtracted to form the shape and orientation of the abutment.

[0032] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described.

[0033] Although the foregoing detailed description of the present invention has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall with in the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0034] Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

[0035] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.