Modeling and manufacturing of dentures

Abstract

Disclosed is a method for modeling and manufacturing a denture for a patient, where the denture comprises a gingival part and artificial teeth, wherein the method comprises: providing a 3D scan comprising at least part of the patient's oral cavity; virtually modeling at least part of the denture using the 3D scan; obtaining virtual teeth to represent the artificial teeth; virtually modeling at least one of the virtual teeth to obtain a set of modeled virtual teeth; manufacturing the modeled virtual teeth in a first material; manufacturing the gingival part in a second material; and manufacturing at least part of the denture by means of computer aided manufacturing (CAM).

Claims

1. A method for modeling and manufacturing a denture for a patient, where the denture comprises a gingival part and artificial teeth, wherein the method comprises: virtually modeling at least part of the denture using a 3D scan comprising at least part of the patient's oral cavity; obtaining virtual teeth to represent the artificial teeth; virtually modeling at least one of the virtual teeth to obtain a set of modeled virtual teeth; overlaying and/or morphing a scan made of a try-in of the denture before testing in the patient's mouth with a scan made of the try-in after testing the try-in in the patient's mouth and adjusting the try-in based on the testing; automatically detecting chanties between the scan made before testing with the scan made after testing; modifying the denture based on the detected changes; manufacturing the modeled virtual teeth in a first material; manufacturing the gingival part in a second material; and manufacturing at least part of the denture by means of computer aided manufacturing (CAM).

2. The method according to claim 1, wherein the method comprises virtually modeling attachment of the artificial teeth in the gingival part.

3. The method according to claim 2, wherein the virtual modeling of the attachment of the artificial teeth in the gingival part comprises offsetting at least a part of the artificial teeth and/or at least part of the gingival part.

4. The method according to claim 1, wherein the method further comprises modeling and manufacturing holes in the gingival part to receive the manufactured teeth.

5. The method according to claim 2, wherein the attachment of the artificial teeth in the gingival part is obtained by means of interlocking features.

6. The method according to claim 1, wherein the artificial teeth are attached in the gingival part by means of providing a bore in the area of the artificial teeth which is adapted to be arranged in the hole in the gingival part, and arranging a bar in the bore, where the bar is adapted to extend to the gingival part for retaining the artificial teeth in the gingival part.

7. The method according to claim 1, wherein the method further comprises obtaining the virtual teeth by selection from among a number of virtual, pre-designed teeth.

8. The method according to claim 1, wherein the method further comprises modeling the gingival part based on a determined occlusal plane.

9. The method according to claim 1, wherein the method further comprises applying stipple wax pattern on the gingival part.

10. The method according to claim 1, wherein the virtual teeth are a composed set of teeth comprising a number of teeth arranged spatially relative to each other forming a high functional and aesthetic composition.

11. The method according to claim 1, wherein the method further comprises collectively modifying one or more parameters of the teeth in the composed set of teeth.

12. The method according to claim 1, wherein the denture is adapted to be attached to dental implants and/or on dental implant bars or bridges.

13. The method according to claim 1, wherein the denture is adapted to be attached to a partial removable framework.

14. The method according to claim 13, wherein the method further comprises collectively modeling the partial removable framework and the denture comprising the manufactured teeth and the gingival part.

15. The method according to claim 1, wherein the method further comprises the steps of: manufacturing the try-in comprising at least a try-in gingival; testing the try-in in the patient's mouth; and if the try-in does not fit perfectly, adjusting the try-in to fit in the patient's mouth.

16. The method according to claim 15, wherein the method further comprises scanning the try-in after testing in the patient's mouth and optional adjustment.

17. The method according to claim 15, wherein the try-in gingival is made in a material which is subject to hardening.

18. The method according to claim 15, where after the try-in has been tested in the patient's mouth and optionally adjusted, the method further comprises hardening the try-in gingival, and providing the try-in gingival to be at least part of the denture.

19. The method according to claim 15, wherein after the try-in has been tested in the patient's mouth and optionally adjusted, a gingival part is modeled based on the optionally adjusted try-in and printed in a hard material.

20. The method according to claim 1, wherein the method further comprises positioning a virtual alignment plane relative to the virtual upper jaw and the virtual lower jaw.

21. The method according to claim 1, wherein the method further comprises automatic movement of the virtual alignment plane relative to the movement of the virtual teeth in the denture, when the virtual teeth are being modeled.

22. A method for modeling a denture for a patient, where the denture comprises a gingival part and artificial teeth, wherein the method comprises the steps of: virtually modeling at least part of the denture using a 3D scan comprising at least part of the patient's oral cavity; obtaining virtual teeth to represent the artificial teeth; virtually modeling at least one of the virtual teeth to obtain a set of modeled virtual teeth; overlaying and/or morphing a scan made of a try-in of the denture before testing in the patient's mouth with a scan made of the try-in after testing the try-in in the patient's mouth and adjusting the try-in based on the testing; automatically detecting changes between the scan made before testing with the scan made after testing; and modifying the denture based on the detected changes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and/or additional objects, features and advantages of the present invention, will be further elucidated by the following illustrative and non-limiting detailed description of embodiments of the present invention, with reference to the appended drawings, wherein:

(2) FIG. 1 shows an example of a flow chart of the method.

(3) FIGS. 2a) to 2c) show examples of manufactured dentures.

(4) FIGS. 3a) and 3b) show examples of virtual modeling of dentures.

(5) FIGS. 4a) to 4c) show examples of different implant bars.

(6) FIGS. 5a) to 5c) show examples of different attachment types.

(7) FIGS. 6a) and 6b) show examples of implant bridges.

(8) FIG. 7 shows an example of combination of different CAD modeling for a set of teeth.

(9) FIGS. 8a) and 8b) show an example of a how a denture and a partial removable framework are attached to each other.

(10) FIGS. 9a) and 9b) show examples of modeling the gingival part.

(11) FIGS. 10a) to 10f) show examples of attachment of the artificial teeth in the gingival part.

(12) FIG. 11 shows an example of a flow chart of an aspect of the method.

DETAILED DESCRIPTION

(13) In the following description, reference is made to the accompanying figures, which show by way of illustration how the invention may be practiced.

(14) FIG. 1 shows an example of a flow chart of the method for computer-aided modeling and computer-aided manufacturing of a denture comprising a gingival part and artificial teeth.

(15) In step 101 a 3D scan comprising at least part of the patient's oral cavity os provided.

(16) In step 102 at least part of the denture is virtually modeled using the 3D scan.

(17) In step 103 virtual teeth is obtained to represent the artificial teeth.

(18) In step 104 at least one of the virtual teeth is virtually modeled to obtain a set of modeled virtual teeth.

(19) In step 105 the modeled virtual teeth is manufactured in a first material.

(20) In step 106 the gingival part is manufactured in a second material.

(21) In step 107 at least part of the denture is manufactured by means of computer aided manufacturing (CAM).

(22) FIG. 2 shows examples of manufactured dentures.

(23) FIG. 2a) shows pictures of a denture 201 which is, or is a part of, or comprises a partial denture. The partial denture 201 comprises a framework 206 and a gingival part 203 and a teeth part comprising artificial acrylic teeth 205.

(24) In the top image, the partial denture is arranged next to a model of the patient's present teeth, and the denture is seen from below, i.e. from the side pointing towards the palate.

(25) In the bottom image, the partial denture is arranged on the model of the patient's teeth, and the denture is seen from above, i.e. from the side pointing towards the surroundings when the denture is arranged in the mouth of the patient.

(26) FIG. 2b) shows pictures of an upper denture 201 and a lower denture, which are both partial dentures. The partial dentures 201 comprise a framework 206 and a gingival part 203 and the top image also shows a teeth part comprising artificial acrylic teeth 205.

(27) In the top image, the partial dentures are arranged on the models of the patient's present teeth, and the dentures are seen from above or from the frontside.

(28) In the bottom image, the partial dentures are arranged next to the models of the patient's teeth, and the dentures are seen from below or from the backside. In the bottom image the dentures are shown without the artificial teeth or the veneering of the metal framework.

(29) FIG. 2c) shows pictures of a denture 201 which is a full maxillary denture, i.e. a denture for the upper arch. The denture 201 comprises a gingival part 203 and a teeth part comprising artificial teeth 205 made of acrylics.

(30) In the top image, the partial denture is arranged on the model of the patient's present teeth, and the denture is seen from above or from the frontside.

(31) In the bottom image, the partial denture is arranged next to the model of the patient's teeth, and the denture is seen from below or from the backside.

(32) The denture 201 shown in FIG. 2c) is a removable denture, and it is not attached to the mouth by any attachment means when in use, so the patient can at any time remove the denture. The denture 201 of FIG. 2c) is held in place in the patient's mouth by means of friction, suction, negative pressure etc.

(33) The dentures 201 of FIG. 2a) and FIG. 2b) may be removable for the patient, however alternatively the dentures may be attached to the existing teeth by some attachment means, which only the dentist should manage.

(34) InteraDent Zahntechnik GmbH in Lbeck, Germany has provided the images of the different dentures shown in FIG. 2.

(35) FIG. 3 shows examples of virtual modeling of dentures.

(36) FIG. 3a) shows an example of virtual modeling of an implant bar for implants and denture.

(37) The virtual denture 301 comprises a virtual teeth part 304 comprising virtual teeth 305, and a virtual gingival part 303. Inside the virtual denture 301 which is transparent, a virtual implant bar 307 is seen and marked with dots above it. A number of virtual implant screws 308 are also seen sticking out underneath the denture 301. The implant screws 308 are attached to the implant bar 307. A part of a scan 302 of the patient's jaw is also seen inside the denture 301.

(38) The implant bar 307 is modeled for optimal fit to the denture 301 and implants 308 using virtual tools in the computer aided drawing (CAD) software. Virtual measurements can be performed to validate space and distances of the denture 301, the scan 302, the implant bar 307, the implants screws 308 etc. The connection from the implant bar 307 to the implants 308 can be shaped as a cylindrical extension, as a freeform emergence profile etc.

(39) FIG. 3b) shows an example of virtual modeling of a removable denture.

(40) A virtually modeled tooth 305 in a partial removable framework is arranged with a distance to the existing gingival 316, and the space 319 between the tooth and the existing gingival is virtually blocked out for avoiding having the denture material between the teeth and the existing gingival when the manufactured denture is worn by the patient. The gingival part 303 is modeled such that the tooth 305 is attached in the gingival part 303.

(41) FIG. 4 shows examples of different implant bars.

(42) FIG. 4a) shows an example of an implant bar 407 for a full denture (not shown). The denture may be a removable denture, i.e. it may be removably attached to the implant bar 407 by means of attachments in the form of e.g. clips (not shown) which can be snapped on and off the implant bar 407.

(43) The implant bar 407 comprises holes 411 for receiving implants.

(44) FIG. 4b) shows an example of an implant bar 407 for a full denture (not shown). The denture may be a removable denture, i.e. it may be removably attached to the implant bar 407 by means of attachments 409 in the form of locators present on both the denture and on the implant bar 407, where the locators 409 provides that the denture can be clicked on and off the implant bar 407.

(45) The implant bar 407 comprises holes 411 for receiving implants.

(46) FIG. 4c) shows an example of an implant bar 407 for a full denture (not shown). The denture may be a fixed denture, i.e. it may be fixedly attached to the implant bar 407 e.g. by gluing part of the denture into the retention holes 410 in the implant bar 407. This may be performed by using acrylics in the denture, and the soft acrylics from the denture will then run into the retention holes 410 of the implant bar 407 and thereby attaching the denture to the implant bar 407.

(47) The implant bar 407 comprises holes 411 for receiving implants.

(48) FIG. 5 shows examples of different attachment types.

(49) FIG. 5a) shows an attachment in the form of a locator 509. The locator 509 may comprise a male part on e.g. the implant bar and a female part on e.g. the denture or vice versa, and the male part and the female part may work as a button.

(50) FIG. 5b) shows an attachment in the form of a ball attachment 509.

(51) FIG. 5c) shows an attachment in the form of retention holes 510.

(52) Another type of attachment may be a slide attachment, however any kind of attachment from a CAD library may be used.

(53) When modeling the denture and implant, the different kinds of attachments can be added anywhere on the implant bar, and the attachments can then be rotated and translated for fine-adjustment of their position and angles.

(54) FIG. 6 shows examples of implant bridges.

(55) FIG. 6a) shows an example of an implant bridge 607 onto which a full denture is adapted to be arranged. On the side opposite to where the denture should be attached, the implant bridge 607 comprises protrusions 612 from holes for receiving implants (not shown).

(56) FIG. 6b) shows an example of an implant bridge 607 comprising pins 613 where each pin is adapted to receive an artificial tooth having a hole in it for fitting over the pin, or where the pin is adapted to be covered by veneering in the form of e.g. ceramics or composite material for resembling teeth. Thus in this case the denture may be defined as comprising the artificial teeth attached onto the pins, or the denture may be defined as the veneering resembling teeth. On the side opposite to the pins 613, the implant bridge 607 comprises protrusions 612 from holes for receiving implants (not shown). An original wax-up bar design may be scanned for remodeling the implant bar in a new material to create a digitized file that is suitable for e.g. copy milling. Adjustments to the digitized model can be applied to achieve the optimal copy milling result.

(57) FIG. 7 shows an example of combination of different CAD modeling for a set of teeth.

(58) All restorations may be designed in the same modeling session using embodiments of the present method. When all restorations are modeled in the same session the efficiency and clinical result will be improved.

(59) FIG. 7 shows a standard bridge 714, full anatomical crowns 715, an implant bridge 707 and implants 708. A denture should also be modeled using CAD and after manufacturing be attached to the implant bridge 707 and e.g. on the standard bridge 714. Alternatively, veneering can be applied to the standard bridge to make it an anatomical bridge, e.g. veneering in the form of porcelain.

(60) FIG. 8 shows an example of a how a denture and a partial removable framework are attached to each other.

(61) FIG. 8a) shows a partial removable framework 806 with retention grid and holes 817 but without artificial teeth or gingival attached.

(62) FIG. 8b) shows a cross section of a denture with a partial removable framework, for example as those seen in FIGS. 2a) and 2b). The partial removable framework 806 is embedded in the gingival part 803, since the gingival part 803 is both present above and below the framework 806. An artificial tooth 805 is arranged in the gingival part, and the gingival part 803 rests on the patient's real physiological gingival 816.

(63) If the gingival part 803 is poured in silicone, then the liquid silicone can flow into the holes of the retention grid 817 in the framework 806. But if the gingival part 803 is printed, then there is no liquid silicone to flow into the holes of the retention grid 817. For the framework 806 and the gingival part 803 to be attached to each other, the gingival part 803 may then be separated as indicated by the separation line 818 into two or more pieces which can then be assembled around the framework 806. The separation line(s) 818 can be at other places in the gingival part 803, e.g. vertical instead of horizontal etc. Alternatively and/or additionally, the framework 806 including the retention grid 817 can be separated into two or more pieces.

(64) FIG. 9 shows examples of modeling the gingival part.

(65) FIG. 9a) shows points 920 marked on the teeth 905 for indicating that the gingival part 903 should end there. A first offset 921, marked by arrows, of the gingival part 903 from the existing gingival 916 may be determined, an second offset, marked by arrows, 922 of the gingival part 903 from the teeth 905 may be determined, a smooth transition 923 connecting the first offset 921 from the existing gingival 916 and the second offset 922 from the teeth may be performed using a lofting operation.

(66) FIG. 9b) shows an example of offsetting 922, marked by arrows, the gingival part 903 around the virtual teeth 905. By offsetting the gingival part 903 around the virtual teeth 903 and finally around the manufactured teeth, the gingival part 903 will look more natural since this is how the physiological gingival looks.

(67) FIG. 10 shows examples of attachment of the artificial teeth in the gingival part.

(68) FIG. 10a) shows an example where holes 1024 are modeled and manufactured in the gingival part 1003 to receive the manufactured teeth. In the figure 14 holes 1024 are provided, and thus this denture is configured for receiving 14 artificial teeth, which may be all the teeth of the lower or upper jaw of a patient. Thus this is a full denture for the upper or lower jaw. Fewer holes 1024 may be manufactured in the gingival part 1003, if the denture is not a full denture, but a partial denture.

(69) FIG. 10b) shows an example where the hole 1024 in the gingival part comprises undercuts 1025, whereby the artificial tooth 1006 can be attached in the hole 1024 by press-fitting.

(70) FIG. 10c) shows an example where the artificial tooth 1005 is attached in the hole 1024 of the gingival part by means of a fastening means in the form of a screw 1026 in the bottom of the hole 1024. A screw hole 1027 is manufactured in the bottom of the hole 1024, and a screw hole 1028 is manufactured in the bottom of the artificial tooth 1005.

(71) FIG. 10d) shows an example where the artificial tooth 1005 is attached in the hole 1024 in the gingival part by means of ball-shaped interlocking features 1029, 1030. The part of the interlocking feature in the hole 1024 may be denoted the hole interlocking feature 1029, and the part of the interlocking feature in the artificial tooth 1005 may be denoted the tooth interlocking feature 1030. The hole interlocking feature 1029 and the tooth interlocking feature 1030 match each other such that the tooth 1005 is fixed in the hole 1024 in the gingival part by means of the interlocking features 1029 and 1030.

(72) There may be one or more, such as one, two, three, four or five sets of interlocking features for each artificial tooth.

(73) The tooth interlocking feature 1030 may be configured to be pushed in to align with the plane surface of the tooth where it is arranged, for example when pressure is applied to the interlocking feature 1030, e.g. when a machine or a dental technician presses the interlocking feature 1030 in for pushing the artificial tooth 1005 in the hole 1024 in the gingival. When the artificial tooth 1005 has been pushed down into the hole 1024, the tooth interlocking feature 1030 is configured to push out again and file the space in the side wall of the hole 1024 provided by the corresponding hole interlocking feature 1029.

(74) FIG. 10e) shows an example where the artificial tooth 1005 is attached in the hole 1024 in the gingival part by means of ball-shaped interlocking features 1029, 1030. The part of the interlocking feature in the hole 1024 may be denoted the hole interlocking feature 1029, and the part of the interlocking feature in the artificial tooth 1005 may be denoted the tooth interlocking feature 1030. The hole interlocking feature 1029 and the tooth interlocking feature 1030 match each other such that the tooth 1005 is fixed in the hole 1024 in the gingival part by means of the interlocking features 1029 and 1030.

(75) There may be one or more, such as one, two, three, four or five sets of interlocking features for each artificial tooth.

(76) The hole interlocking feature 1029 may be configured to be pushed in to align with the plane surface of the wall of the hole 1024 where it is arranged, for example when pressure is applied to the interlocking feature 1029, e.g. when a machine or a dental technician pushes the artificial tooth 1005 into the hole 1024 in the gingival. When the artificial tooth 1005 has been pushed down into the hole 1024, the hole interlocking feature 1029 is configured to push out again and file the space in the side wall of the tooth 1005 provided by the corresponding tooth interlocking feature 1030.

(77) FIG. 10f) shows an example where the artificial tooth 1005 is attached in the gingival part by means of providing a bore 1031 in the area of the artificial teeth which is adapted to be arranged in the hole 1024 in the gingival part, and arranging a bar 1032 in the bore 1031, where the bar 1032 is adapted to extend outside the hole 1024 of the gingival part 1003 for retaining the artificial tooth 1005 in the gingival part 1003. The hole 1024 in the gingival part 1003 may comprises holes 1033 in the side walls of the hole 1024 such that the bar 1032 can fit in the hole 1024.

(78) Alternatively and/or additionally the artificial teeth may be attached, e.g. in holes, in the gingival part by means of glue, cement, tape, vacuum or negative pressure created by means of moisture in the patient's mouth etc.

(79) FIG. 11 shows an example of a flow chart of the method for computer-aided modeling and computer-aided manufacturing of a denture comprising a gingival part and artificial teeth.

(80) In step 101 a 3D scan comprising at least part of the patient's oral cavity os provided.

(81) In step 102 at least part of the denture is virtually modeled using the 3D scan.

(82) In step 103 virtual teeth is obtained to represent the artificial teeth.

(83) In step 104 at least one of the virtual teeth is virtually modeled to obtain a set of modeled virtual teeth.

(84) In step 105 attachment of the artificial teeth in the gingival part is virtually modeling for securing an fixing the artificial teeth in the gingival part.

(85) In step 106 the modeled virtual teeth is manufactured in a first material.

(86) In step 107 the gingival part is manufactured in a second material.

(87) At least part of the denture is manufactured by means of computer aided manufacturing (CAM).

(88) Although some embodiments have been described and shown in detail, the invention is not restricted to them, but may also be embodied in other ways within the scope of the subject matter defined in the following claims. In particular, it is to be understood that other embodiments may be utilised and structural and functional modifications may be made without departing from the scope of the present invention.

(89) In device claims enumerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage.

(90) It should be emphasized that the term comprises/comprising when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

(91) The features of the method described above and in the following may be implemented in software and carried out on a data processing system or other processing means caused by the execution of computer-executable instructions. The instructions may be program code means loaded in a memory, such as a RAM, from a storage medium or from another computer via a computer network. Alternatively, the described features may be implemented by hardwired circuitry instead of software or in combination with software.