Method and system for fabricating a dental coping, and a coping fabricated thereby

Abstract

A wax model of a required coping is produced using CNC machining techniques based on a virtual model of the coping created from digital data obtained from the intraoral cavity. The dental coping is then fabricated from the wax model.

Claims

1. A system for fabricating a wax model of a dental coping shaped to fit over a tooth preparation in a patient's intraoral cavity, the system comprising: a wax material configured to be fabricated into the wax model of the dental coping; a milling machine configured to fabricate the wax model of the dental coping from the wax material; and one or more computer-readable storage media comprising instructions that, when executed by a processor, cause the processor to: receive 3D digital data of the patient's intraoral cavity comprising the tooth preparation, the 3D digital data comprising an enamel thickness of the tooth preparation, generate, in response to the 3D digital data, a 3D virtual model of a dental coping based on the enamel thickness comprising an inner surface shaped to fit over at least a portion of the tooth preparation and an outer surface disposed between the inner surface and an outer surface of a tooth prosthesis, wherein the 3D virtual model of the dental coping is generated based on the enamel thickness of the tooth preparation, generate a computerized numerical control (CNC) set of wax fabrication instructions for fabricating the wax model of the dental coping based on the 3D virtual model of the dental coping, and transmit the CNC set of wax fabrication instructions to the milling machine, wherein the CNC set of wax fabrication instructions is configured to cause the milling machine to fabricate the wax model of the dental coping from the wax material.

2. The system of claim 1, wherein the wax material is configured to be used in a lost wax process for fabricating the dental coping.

3. The system of claim 2, wherein the wax material comprises one or more of: a melting point from about 55° C. to about 80° C., a congealing point from about 55° C. to about 80° C., or a kinematic viscosity of less than about 90 m.sup.2/sec at about 100° C.

4. The system of claim 1, wherein the 3D virtual model of the dental coping comprises finish line data corresponding to a finish line of the tooth preparation.

5. The system of claim 4, wherein the finish line data is generated based on user input received by the processor.

6. The system of claim 4, wherein the finish line data is generated automatically by the processor.

7. The system of claim 1, wherein the 3D virtual model of the dental coping is generated according to a specified coping thickness for the dental coping.

8. The system of claim 1, wherein the 3D digital data comprises surface topology data of the patient's intraoral cavity.

9. The system of claim 8, wherein the surface topology data is generated by an optical scanner utilizing confocal focusing of an array of light beams.

10. The system of claim 1, wherein the tooth preparation comprises one or more tooth stumps, implants, or pivots.

11. The system of claim 1, wherein the tooth prosthesis comprises a crown prosthesis or a bridge prosthesis.

12. A method for fabricating a wax model of a dental coping shaped to fit over a tooth preparation in a patient's intraoral cavity, the method comprising: providing a wax material configured to be fabricated into the wax model of the dental coping; providing a milling machine configured to fabricate the wax model of the dental coping from the wax material; and providing one or more computer-readable storage media comprising instructions that, when executed by a processor, cause the processor to: receive 3D digital data of the patient's intraoral cavity comprising the tooth preparation, the 3D digital data comprising an enamel thickness of the tooth preparation, generate, in response to the 3D digital data, a 3D virtual model of a dental coping based on the enamel thickness comprising an inner surface shaped to fit over at least a portion of the tooth preparation and an outer surface disposed between the inner surface and an outer surface of a tooth prosthesis, wherein the 3D virtual model of the dental coping is generated based on the enamel thickness of the tooth preparation, generate a computerized numerical control (CNC) set of wax fabrication instructions for fabricating the wax model of the dental coping based on the 3D virtual model of the dental coping, and transmit the CNC set of wax fabrication instructions to the milling machine, wherein the CNC set of wax fabrication instructions is configured to cause the milling machine to fabricate the wax model of the dental coping from the wax material.

13. The method of claim 12, wherein the wax material is configured to be used in a lost wax process for fabricating the dental coping.

14. The method of claim 13, wherein the wax material comprises one or more of: a melting point from about 55° C. to about 80° C., a congealing point from about 55° C. to about 80° C., or a kinematic viscosity of less than about 90 m.sup.2/sec at about 100° C.

15. The method of claim 12, wherein the 3D virtual model of the dental coping comprises finish line data corresponding to a finish line of the tooth preparation.

16. The method of claim 15, wherein the finish line data is generated based on user input received by the processor.

17. The method of claim 15, wherein the finish line data is generated automatically by the processor.

18. The method of claim 12, wherein the 3D virtual model of the dental coping is generated according to a specified coping thickness for the dental coping.

19. The method of claim 12, wherein the 3D digital data comprises surface topology data of the patient's intraoral cavity.

20. The method of claim 19, wherein the surface topology data is generated by an optical scanner utilizing confocal focusing of an array of light beams.

21. The method of claim 12, wherein the tooth preparation comprises one or more tooth stumps, implants, or pivots.

22. The method of claim 12, wherein the tooth prosthesis comprises a crown prosthesis or a bridge prosthesis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order to understand the invention and to see how it may be carried out in practice, a preferred embodiment will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

(2) FIGS. 1A-1E illustrate an exemplary scenario for the fabrication of a dental coping in which the invention is implemented;

(3) FIG. 2 shows a block diagram of fabrication processes according to the invention.

(4) FIG. 3 shows a block diagram of fabrication system according to the invention.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

(5) FIGS. 1A-1E illustrate an exemplary scenario for the fabrication of a dental coping in which the invention is implemented. The scenario is carried out with the aid of a computer system, the operation of which will be explained later on. FIG. 1A shows a section 10 of a patient's teeth (part of the patient's upper jaw, in this example), in which tooth prosthesis is to be fitted over tooth preparation 12. In the example of FIG. 1A, the root and base of the tooth 12 are sufficiently strong and healthy, and the care provider prepared the tooth for the crown by removing a portion of the enamel and dentin. If the tooth to be restored is severely decayed or weak, then it may be necessary to insert a metal implant or pivot (also known as cores or posts) by any one of a number of ways known per se.

(6) An exemplary system 300 for carrying out the process of the invention is illustrated in FIG. 3.

(7) The 3D digitized data of the intraoral cavity, including the dentition and associated anatomical structures of a patient is obtained, and thus suitable equipment for scanning a patient's teeth is used by the care provider to acquire the 3D data. The production of the virtual 3D working model of the preparation and its surroundings is known per-se.

(8) As shown in FIG. 1B, for example, the care provider captures an image of the preparation and its surroundings with a probing device 20. Advantageously, a probe for determining three dimensional structure by confocal focusing of an array of light beams may be used, for example as manufactured under the name of PROSTHOCAD or as disclosed in WO 00/08415, the contents of which are incorporated herein in their entirety. Alternatively, scanning of the dental cavity to provide the 3D data may be accomplished using a suitable apparatus, for example as disclosed in any one of U.S. Pat. No. 4,837,732, U.S. Pat. No. 4,611,288, U.S. Pat. No. 6,594,539, U.S. Pat. No. 6,402,707, U.S. Pat. No. 6,364,660, US 2002/0028418, US 2002/0058229, U.S. Pat. No. 5,652,709, U.S. Pat. No. 4,575,805, U.S. Pat. No. 5,733,126, U.S. Pat. No. 5,880,962, U.S. Pat. No. 4,742,464, U.S. Pat. No. 4,663,720, WO 02/071306 mutatis mutandis. The contents of these publications are incorporated herein in their entirety by reference thereto.

(9) The 3D data obtained by the probe may then be stored in a suitable storage medium, for example a memory in a computer workstation, for further processing, as described herein.

(10) Alternatively, a negative cast or impression is taken of the patient's teeth, in a manner known in the art, and this negative model and a positive cast is made from this model suitable for scanning. The positive cast may be scanned by any method known in the art, including using the aforesaid probe manufactured under the name of PROSTHOCAD or as disclosed in WO 00/08415. Alternatively, the negative model itself may be scanned.

(11) Alternatively, a composite positive-negative model may be manufactured from the original negative model. Thereafter, the positive-negative model may be processed to obtain 3D digitized data, for example as disclosed in U.S. Pat. No. 6,099,314, assigned to the present assignee, and the contents of which are incorporated herein in their entirety.

(12) Alternatively, the 3D digitized data may be obtained in any other suitable manner, including other suitable intra oral scanning techniques, based on optical methods, direct contact methods or any other means, applied directly to the patient's dentition. Alternatively, X-ray based, CT based, MRI based, or any other type of scanning of the patient or of a positive and/or negative model of the intra-oral cavity may be used. The digitized data may be associated with a complete dentition, or of a partial dentition, for example such as a preparation only of the intra oral cavity.

(13) Referring to FIG. 3, a virtual 3D working model 22 is digitally produced by a processor, 29 and may well be displayed on display 24.

(14) FIG. 1C shows the virtual working model 22 in a magnified manner, with its finish line 26 (also known as the margin line) that was either generated automatically or marked by the care provider. The virtual model 22 and the finish line 26 data, and perhaps additional 3D data that relates to the patient's dentition, are processed and then input to a CAD (Computer-Aided Design) unit (not shown) that allows for the digital design of the dental coping, resulting in the virtual coping 30, shown in FIG. 1D.

(15) The virtual coping 30 may then be further processed by a CAM (Computer-Aided Manufacture) unit (not shown) to generate a digital set of instructions T that are fed into a CNC (computerized numerical control) milling machine 260, from which a wax coping 40 (as the one shown in FIG. 1E) is milled using wax or the like supplied from supply 270. Wax coping 40 is made of relatively hard, durable wax or similar material. In particular, the coping 40 is made from a material that on the one hand lends itself to milling in a milling machine, while on the other hand has a low melting point and after melting, it has a kinematic viscosity sufficiently low to be usable in a lost wax technique known per se in the art of metal casting. Preferably, such a material has a melting point and congealing point of about 55° C. to about 80° C. and a kinematic viscosity of less than 90 m.sup.2 sec. at about 100° C.

(16) The desired dental coping 90 is then produced from the wax coping, according to common dental practice, via suitable manufacturing means 280.

(17) The finish line data can be generated for example, in a manner disclosed in U.S. Ser. No. 10/623,707 and WO 04/008981 also assigned to the present assignee, and the contents of which are incorporated herein in their entirety. Alternatively, the finish line may be generated using methods disclosed in U.S. Pat. No. 5,266,030 the contents of which are incorporated herein. The virtual generation of the finish line may be incorporated as an integral component in the method of the invention.

(18) The additional 3D data that relates to the patient's dentition includes, inter-alia, information relating to the surrounding of the tooth to be restored, e.g. 3D representation of the patient's dentition, including the upper and lower jaws and their occlusion relationship. Such information is needed, e.g. for the design of the dental crown, and can be generated for example, as disclosed in U.S. Pat. No. 6,099,314 and U.S. Pat. No. 6,334,853.

(19) The virtual model of the desired coping can be generated in several ways. According to one possible way, the care provider designs the overall outer surface of the tooth prosthesis, based on known considerations such as enamel thickness, as well as coping thickness and others. The coping is designed so as to fit below the surface of the tooth prosthesis and over the tooth preparation. By another example, the coping is designed primarily on the basis of the surface topology of the preparation and other factors such as the coping wall's thickness, finish line data, etc.

(20) In particular, the external surface of the coping, which eventually mates with a cap or the like which may be single-layered or multi-layered, is designed according to predetermined criteria, as known in the art, to provide the required mechanical properties required from the restoration.

(21) The virtual coping 30 may also be created in other ways. For example, a physical model of the restoration may be created in any suitable manner, for example as disclosed in U.S. Pat. No. 5,382,164, the contents of which are incorporated herein in their entirety. The inner surface of such a model, preferably including the finish line, may be scanned in any suitable manner, similar, for, example to that described above for the preparation, mutatis mutandis, Alternatively, a virtual model of the full restoration may be used to provide the internal surface and preferably the finish line for the coping. Then, an external surface for the coping may be designed according to any suitable criteria, for example as described above, and the virtual model corresponding to the external surface may be joined to the virtual model of the inner surface to provide the virtual coping 30.

(22) The method of the present invention in fact makes use of the “lost wax” technique, by utilizing relatively hard, durable wax, which can be milled to the desired pattern by a CNC milling machine.

(23) FIG. 2 shows a block diagram of fabrication processes 100 according to the invention. At step 110, a three-dimensional (3D) digital data is provided. The 3D digital data relates to the patient's dentition, including data representative of the surface topology of the preparation and its surroundings. At step 120, a 3D virtual model of a dental coping is generated.

(24) At step 130, a CNC (Computerized Numerical Control) set of instructions corresponding to the 3D virtual model of the desired coping is generated, and fed into a CNC milling machine for the fabrication of a wax coping (step 140), wherein a wax coping is produced from a suitable block of wax or the like.

(25) Optionally, and particularly when the final prosthesis is a bridge, wax replicas of suitable connectors and/or one or more pontics are made, either manually or by any suitable method, including machining, casting and so on, indicated at 240 in FIG. 3. Then, the connectors and/or pontics are joined to the wax copings of the abutment teeth in a suitable manner, for example as is known in the art per se. The metal or ceramic structure for the bridge is then made from the wax model thereof in a similar manner to that described below for a single coping, mutatis mutandis.

(26) At step 150, the dental coping is fabricated from the wax coping. This may be accomplished in any number of ways, known per se in the art. For example, the wax coping is invested in a material that solidifies onto the external side of the wax coping and forms a mold. After the investment stage, the combined structure is then heated such that the wax is burnt out, leaving a cavity. Into this cavity, a suitable molten metal may be injected, and after hardening, the mold is removed from the metal casting to provide a metal coping. Such a lost wax process may be similar to the process used for the production of restorations as described by Ivoclar Vivadent Ltd. regarding the IPS Empress system in http://www.ivoclar.co.uk/technician/nonmetal2.html, mutatis mutandis, for example Alternatively, a suitable ceramic molding composition may be pressed into the cavity, for example as described in U.S. Pat. No. 6,126,732, mutatis mutandis, the contents of which are incorporated herein in their entirety. Alternatively, sintering methods may be applied to the mold to produce a ceramic coping.

(27) Alternatively, the wax coping may be scanned and the coping produced in a manner similar to the production of crowns and bridges, as described by DeguDent regarding the Cercon system in http://www.degudent.com/Products/Cercon_smart_ceramics/index.asp, mutatis mutandis.

(28) The dental coping manufactured according to the present invention is thus derived from a wax model, which due to its relatively softness can be machined to a smoother surface texture than is possible when machining the coping directly from the desired final material such as metal or a ceramic. Accordingly, dental copings produced using the method of the invention using the wax for preparing a mold are correspondingly smoother, and furthermore it is possible to include fine details in the final coping, with respect to copings produced using direct material removal methods applied to the final material.

(29) Furthermore, the wax-based method of the present invention for producing the dental coping has some advantages over direct material removal methods that are used elsewhere for producing the coping directly from the desired final material. For example less wear and breakage are experienced by the machining tool, and thus lowers costs. Furthermore, deformations of the tool, when a direct contact tool such as for example a mechanical tool is used, is less likely, and thus less deviations from the nominal dimensions of the coping with respect to the virtual model thereof occur than when producing a coping directly from a metal or other hard material.

(30) The invention allows to gather the 3D data that represents the patient's dentition in one place (say, the care provider's clinic), to design the virtual coping model at the clinic or at a remote location, to generate the CNC set of instructions at another place and to fabricate the wax coping at a yet another location. Furthermore, the invention allows for the fabrication of the wax coping and the dental coping at different locations without damaging the quality of the dental coping due to deformations in the coping wax model. It should be noted that additional, intermediate steps in which digital data is transmitted between remote locations might be carried-out as part of method 100, for example between steps 110 and 120, etc.

(31) The invention is not bound by the specified example of FIGS. 1A-1E and, accordingly, other scenarios may be used in addition or in lieu of the above, depending upon the particular application. Specifically, the invention can also be utilized in a less “digitized” scenario, for example one in which the care provider gathers the relevant information relating to the patient's dentition in a non-digitized manner (e.g. by taking a physical impression of the patient's dentition), and the patient's dentition data is digitized later on, at a laboratory.

(32) Furthermore, the invention can be utilized for the fabrication of the dental prostheses as a whole, as needed, for example, when restoring the tooth with a gold prosthesis. In that case, a wax model of the desired prosthesis is fabricated, from which a whole metal prosthesis is replicated.