Surgical template

Abstract

An embodiment of the invention provides a method of producing a surgical template comprising the steps of: obtaining a set of 3D surface data, the 3D surface data representing a surface of a patient's oral situation, obtaining a support structure model describing a surgical template configured to fit to a portion of the surface of the patient's oral situation, obtaining planned bore position data, the planned implant position data describing the longitudinal axes of a set of one or more planned implant bore holes relative to the 3D surface data, automatically modifying the support structure model to provide support material for guide holes in the support structure model corresponding to the one or more planned implant bore holes, producing the dental splint in dependence on the modified support structure model.

Claims

1. A method of producing a surgical template: i) obtaining a set of 3D surface data, the 3D surface data representing a surface of a patient's oral situation, ii) obtaining a virtual support structure model describing a dental splint configured to fit to a portion of the surface of the patient's oral situation, iii) obtaining planned bore position data, the planned bore position data describing the longitudinal axes of a set of one or more planned implant bore holes relative to the 3D surface data, iv) automatically modifying the virtual support structure model to provide support material for guide holes in the virtual support structure model corresponding to the one or more planned implant bore holes, v) producing a physical surgical template in dependence on the modified virtual support structure model, wherein the method further comprises, for each bore hole: vi) generating a first 3D distance map image of the support structure model, wherein the first 3D distance map is a voxel image and wherein each voxel in the first 3D distance map image has a value corresponding to the distance from said voxel in the first 3D distance map image to the closest point on the surface of the support structure model, vii) generating a second 3D distance map image of a sleeve support shape for the guide hole, wherein the second 3D distance map is a voxel image and wherein each voxel in the second 3D distance map image has a value corresponding to the distance from said voxel in the second 3D distance map image to the closest point on the surface of the sleeve support shape, the sleeve support shape having a longitudinal axis corresponding to the bore hole, viii) combining the second 3D distance map image of the sleeve support shape with the first 3D distance map image of the support structure model, ix) modifying the support structure model to include support material where the combined voxel values at each point in the combined 3D distance map images correspond to a distance less than a minimum distance.

2. The method of claim 1, wherein the support structure model is modified to remove any portion which overlaps with a punch shape positioned at the mouth of a guide hole and having the same longitudinal axis as the guide hole.

3. The method of claim 1, wherein the support structure model is modified to remove any portion which overlaps with a guide hole shape having the same longitudinal axis as the bore hole.

4. The method of claim 1, wherein the support structure model is modified to remove any portion which overlaps with a glue hole shape having a substantially perpendicular axis to the longitudinal axis of the bore hole.

5. The method of claim 1, wherein the support structure model is modified to remove any portion which overlaps with the 3D surface described by the 3D surface data.

6. The method of claim 5, wherein an enlarged 3D surface corresponding to the 3D surface data is used.

7. The method of claim 1, wherein the support material is added where the combined voxel values at each point in the combined 3D distance map images correspond to less than 2 mm.

8. The method of claim 1, wherein the support structure model is modified to remove any part forming an undercut.

Description

FIGURES

(1) Aspects of the present invention will now be described by way of example with reference to the accompanying drawing. In the drawings:

(2) FIG. 1a shows a 3D surface model of the patient's oral situation.

(3) FIG. 1b shows the 3D surface model of FIG. 1a from a second perspective.

(4) FIG. 2a shows a horizontal slice of a distance map of the 3D surface data of the patient's oral situation.

(5) FIG. 2b shows a coronal slice (left-right cross-sectional) of the 3D surface data of the patient's oral situation

(6) FIG. 3a shows a transparent support structure model and the 3D surface model of FIG. 1b beneath.

(7) FIG. 3b shows the support structure model of FIG. 3a without any transparency.

(8) FIG. 4 shows a horizontal slice of a distance map of the 3D surface data of the patient's oral situation including an indication of the dental arc.

(9) FIG. 5a shows a panoramic maximum intensity projection of a distance map image.

(10) FIG. 5b shows FIG. 5a with a high point line, delineating the upper edge of the 3D surface model.

(11) FIG. 5c shows the high point line of FIG. 5b lowered by a distance to form a cut-off line to be used on the buccal side of the support structure.

(12) FIG. 5d shows the cut-off line of FIG. 5c after smoothing.

(13) FIG. 5e shows a straight cut-off line used on the lingual side of the support structure.

(14) FIG. 5f shows the determination of the buccal or lingual voxel locations on the support structure.

(15) FIG. 6a shows the support structure model of FIG. 3a with an applied cut-off on the buccal side based on the cut-off line of FIG. 5d and cut-off on the lingual side based on the cut-off line of FIG. 5e.

(16) FIG. 6b shows the support structure model of FIG. 6a from a second perspective.

(17) FIG. 7a shows a panoramic maximum intensity projection of a distance map image of a second patient with a cut-off line.

(18) FIG. 7b shows the cut-off line of FIG. 7a further lowered around a planned anchor pin site.

(19) FIG. 7c shows the cut-off line of FIG. 7b after smoothing.

(20) FIG. 8 shows a process flow diagram of the smoothing process for the cut-off line.

(21) FIG. 9a shows a rendered support structure model for the second patient with the applied cut-off line of FIG. 7b.

(22) FIG. 9b shows a rendered support structure model for the second patient with the applied cut-off line of FIG. 7c.

(23) FIG. 10a shows a distance map image of the support structure model of FIG. 10b.

(24) FIG. 10b shows a support structure.

(25) FIG. 10c shows three perspectives of a distance map image of the virtual component of FIG. 10d.

(26) FIG. 10d shows a first virtual component.

(27) FIG. 10e shows a second virtual component.

(28) FIG. 11a shows a support structure model before joining the support structure model material and the sleeve support material.

(29) FIG. 11b shows the support structure model of FIG. 11a after the joining of the support structure model material and sleeve support material around a guide hole.

(30) FIG. 11c shows a joining of support material around two proximal guide holes in the support structure.

(31) FIG. 11d shows the support structure model of 11b after application of the punch.

(32) FIGS. 12a-12c show virtual components that are added or subtracted from the support structure model using Boolean operations on the surfaces.

(33) FIG. 13a shows a combination of the virtual components of FIGS. 12a to 12c.

(34) FIG. 13b shows another combination of the virtual components.

(35) FIG. 14a shows a cross-sectional view of a tooth of the oral situation.

(36) FIG. 14b shows the tooth of FIG. 14a with a support structure model applied and shows a determination of the under-cut voxels to be removed.

(37) FIG. 14c shows the support structure model of FIG. 14b with the under-cut voxels removed.

DESCRIPTION OF EMBODIMENTS

(38) Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

(39) The following description focuses on an embodiment of the present invention applicable to surgical templates for guiding the installation of oral implants. However, it will be appreciated that the invention is not limited to the use of surgical templates, but may be applied to the production of dental splints, e.g. protective mouth guards or other similar applications.

(40) The following is a description of a preferred embodiment of the invention, which is a method of producing a surgical template without the use of a radiographic guide. The same technique can be used to produce a range of dental splint types. Firstly, a set of 3D surface data describing the surface of a patient's oral situation is obtained. Secondly, a virtual surgical template model is generated in dependence on the 3D surface data and the planned implant and anchor pin positions. Thirdly, a physical surgical template is produced from the virtual surgical template model.

(41) Determination of Patient's Oral Situation

(42) The surface of the patient's oral situation is typically the upper or lower occlusal dental arch of the patient, including the soft tissue and teeth on the buccal, occlusal and lingual sides.

(43) The 3D surface data of the patient's oral situation may be obtained using a number of known optical or radiographic imaging techniques. For example, an intra-oral optical scanner used on the patient's mouth would produce 3D surface data suitable for use with this method. Alternative methods include: an optical scan of an impression of the patient's oral situation (processed as required to compensate for the impression being a negative imprint of the oral situation), an optical scan of a die-cast model of the patient's oral situation, a high-resolution 3D X-ray computed tomography (CT) or magnetic resonance imaging (MRI) image of the oral situation combined with a surface detection algorithm.

(44) Both the intra-oral optical scan and the optical or tactile scan of an impression or die-cast model have the advantage of minimal radiation exposure for the patient and high resolution surface scanning. The CT and MRI scanners provide the advantage of visualizing the internal anatomical structures as well.

(45) The present invention can be used for guided implant placement using: a digital model based approach without CT data, a digital model based approach fused with CT data or just a CT/MRI image combined with a surface detection algorithm.

(46) The 3D surface data 110 of the patient's oral situation is preferable stored as vertices and triangles describing the triangulated surface shown in FIGS. 1a and 1b.

(47) Generating the Support Structure Model

(48) A number of techniques may be used to generate the virtual surgical template model from the 3D surface data of the patient's oral situation. A virtual support structure model may be used as an intermediate step in this process.

(49) Preferably, a distance map imaging method is used to process the 3D surface data to form a virtual surgical template model.

(50) The 3D surface data of the patient's oral situation is processed to form a 3D distance map image 200. This is done by starting from an empty voxel image having the same frame of reference as the 3D surface described by the 3D surface data. Each voxel of the distance map image is assigned a value corresponding to the minimum distance of the voxel to the 3D surface described by the 3D surface data. FIG. 2a shows a horizontal slice of a distance map of the patient's oral situation and an outline of the 3D surface 210. FIG. 2b shows a coronal slice of a distance map of the patient's oral situation and an outline of the 3D surface 210.

(51) In one embodiment, for the lower jaw, voxels at the 3D surface or below (i.e within the volume of the 3D surface data which represents the patient's tissues) are assigned a positive value. Voxels that are above the 3D surface are assigned a negative value. The further the voxel lies from the 3D surface, the greater the value (negative or positive) assigned to the voxel. Other embodiments may comprise alternative voxel value configurations.

(52) Once the distance map image is generated, a support structure model is generated comprising all the voxels having a value within a particular range of the distance map image. In one embodiment, all voxels having a value (and thus a particular distance from the 3D surface) between a first value, representing a position close to the 3D surface, and a second value greater than the first value in magnitude, representing a position further away from the 3D surface, are selected to form the support structure. The first value is chosen to select a distance from the 3D surface where the surface of the support structure model begins. The second value is chosen to define the thickness of the support structure, wherein the thickness is dependent on the difference between the first and second values. The resulting support structure model matches the 3D surface and will fit the patient's oral situation. A larger first value provides a larger tolerance between the 3D surface and the support structure. A small amount of play is provided by the tolerance. In a preferred embodiment, the tolerance is between 0.1 mm and 0.5 mm. FIGS. 2a and 2b show an outline for the first value 220 and the second value 230.

(53) In one embodiment, the first and second values are chosen to generate a support structure model containing all voxels with a distance between 0.1 and 2.1 mm above the 3D surface. The resulting support structure model will have a consistent thickness of 2.0 mm. FIGS. 3a and 3b show an embodiment of the support structure model 310 overlying the 3D surface 320 of the patient's oral situation. The support structure model 310 has an apical edge 330. In FIG. 3a, the support structure model is shown partly transparent in order to see the 3D surface beneath.

(54) The advantage of generating a support structure model automatically in this way is that it is accurate and computationally robust to produce. Given just the 3D surface data of the patient's oral situation, a matching support structure model can be produced quickly and accurately using this technique.

(55) The support structure model should also be limited along the dental arc so that it does not stretch all the way up to the molar teeth at the back of the patient's mouth. Instead, a rearward limit is defined. In FIG. 4, limit line 420 shows the rearward or posterior limit of the support structure model along the dental arc.

(56) In an alternative embodiment, a subtractive technique is used to generate the virtual surgical template model from the 3D surface data of the patient's oral situation. In this technique, a predefined shape having a shape approximating a dental splint is provided. Any shape larger than the oral situation of the patient and still small enough to be used as a support structure model would be suitable. The predefined shape is overlaid onto the 3D surface so that they overlap. A boolean operation is then performed to subtract the 3D surface of the 3D surface data from the predefined shape. The resulting shape has the same general shape as the predefined shape but with a surface matching the 3D surface. This resultant shape would be a suitable basis for a support structure.

(57) In another alternative embodiment, a dilation technique is used to generate the virtual surgical template model from the 3D surface data of the patient's oral situation. This comprises the step of creating a binary image of the 3D surface, wherein the voxels inside the 3D surface have a value of 1 and the voxels outside the 3D surface have a value of 0. The resultant image is then dilated to produce an enlarged binary image of the 3D surface. The original binary 3D surface is then subtracted from the enlarged image to form a resultant support structure, having a thickness dependent on the degree to which the dilated image was enlarged over the 3D surface.

(58) In another alternative embodiment, a z-transfer technique is used to generate the virtual surgical template model from the 3D surface data of the patient's oral situation. This comprises using a model of the 3D surface overlaid with a second model of the 3D surface data shifted in the Z-axis. The geometric space between the two 3D surfaces can then be used to form the support structure. This provides a support structure model with a surface matching the patient's oral situation and having a consistent thickness.

(59) Customizing the Support Structure Model

(60) According to the preferred embodiment of the invention, once the support structure model has been generated, it may be further refined to include specific characteristics or features.

(61) As the finalized surgical template will be produced from the support structure model, any changes to the characteristics of the support structure model will also result in changed characteristics of the final surgical template.

(62) Support Structure Model Cut-Off Line

(63) In the preferred embodiment, the support structure model is configured to cover just a coronal portion of the patient's existing teeth or gum surfaces. A cut-off line limiting the support structure model in the apical direction is used. This is achieved in the following way: 1. First, as shown in FIG. 4, a dental arc 410 is determined relative to the distance map image 400. In an alternative embodiment, the arc is determined according to the 3D surface data of the patient's oral situation. In another embodiment, the arc is indicated by the user. 2. Then, a maximum intensity projection of the distance map image 400 is generated along the arc 410, forming a panoramic image shown in FIG. 5a of a lower jaw similar to an orthopantomogram typically used by dentists. Ridge 500 is clearly visible. 3. As shown in FIG. 5b, the highest points (or coronal edge) along the top of ridge 500 are recorded, forming a line 510 defining the upper boundary of the 3D surface data. The highest points are determined as the transition point from the pixels indicating teeth material to the pixels indicating empty space (e.g. the transition between negative and positive values) at each vertical line of the panoramic image. 4. Line 510 is then lowered (away from the occlusal plane) in FIG. 5c. This new line defines the buccal cut-off line 520 of the support structure model along arc 410. For an equivalent upper jaw, the line 510 is raised (also away from the occlusal plane) instead of lowered to form the cut-off line 520. 5. As shown in FIG. 5d, the cut-off line is smoothed. In one embodiment, a moving average algorithm is used to smooth the cut-off line. 6. The support structure model of FIGS. 3a and 3b is then modified to have a buccal edge corresponding to the buccal cut-off line.

(64) In a preferred embodiment, the buccal cut-off line is lowered by between 1 mm and 4 mm. It is understood that for an equivalent upper jaw, the buccal cut-off line is raised instead of lowered.

(65) In the preferred embodiment, two cut-off lines are used. On the buccal side, a cut-off line as described above is used. On the lingual side, as shown in FIG. 5e, the cut-off line 530 is a straight line at a fixed height. This straight line will result in a larger support structure model at the lingual side providing additional strength. As shown in FIG. 5f, in order to automatically determine which side of the support structure model is the buccal side 580 and which side is the lingual side 590, an image is generated from the 3D surface wherein each voxel location is determined to be on the lingual or buccal side. In one embodiment, the step of determining the lingual or buccal side aspect of the voxel is performed by determining at which side of the dental arc the voxel lies.

(66) Examples of the resulting support structure model are shown in FIGS. 6a and 6b.

(67) In one embodiment shown in FIG. 7a in which the final surgical template will be supported by anchor pins inserted into the patient's jaw, the cut-off line on the buccal side is modified to provide additional material around the anchor pin sites. In one embodiment as shown in FIG. 7b, this is done by lowering the cut-off line to include an area defined by a circle 740 around the anchor pin location site 750 on the panoramic maximum intensity projection of the distance map image. This step is only performed at the side were the anchor pin is located, e.g. the buccal or lingual side.

(68) In one embodiment shown in FIG. 7c, the cut-off line of FIG. 7b is smoothed according to the following process shown in FIG. 8: Shown in step 810, a moving average is calculated along the cut-off line. In step 820, the curvature of the cut-off line is determined in each recorded point, defining concave and convex parts. In step 830, only the convex parts of the line are retained for a lower jaw, or only the concave parts are retained for an upper jaw.

(69) A support structure model having a buccal edge based on the unsmoothed cut-off line is shown in FIG. 9a and a support structure model having a buccal edge based on the smoothed cut-off line is shown in FIG. 9b. The second one is clearly preferable for aesthetic and strength reasons and lowers the risk for hurting the patient.

(70) Support Structure Model Guide Holes

(71) In the preferred embodiment, the support structure model is used to form a surgical template for guiding the drilling of bore holes to allow insertion of oral implants into the patient's jaw bone. Consequently, the support structure model is configured with guide holes. The guide holes may be fitted with matching guide sleeves which typically comprise a harder material and which serve the function of guiding the metal drill guide. As the support structure model material around the guide holes will need to withstand a degree of force from the interaction with the surgeon's tools, the support structure model requires reinforcement for supporting the guide sleeves. The reinforcement is done by adding virtual material to the support structure. Furthermore, the tight fit of the support structure model to the patient's dentition means that the top surface of the support structure model is highly variable.

(72) For each guide hole, guide sleeve support material is added to the support structure model by: 1. Determining the position of the guide hole in the support structure model in dependence on the intended position of the intending bore hole in the patient's jaw and corresponding installed implant or anchor pin position. 2. Providing a distance map image 1010 (shown in FIG. 10a) of the support structure model 310 (an embodiment of which is shown in FIG. 10b). 3. Providing a distance map image 1020 (shown in FIG. 10c) of a sleeve support shape 1030 (an embodiment of which is shown in FIG. 10d). 4. Providing an image of a punch shape 1040 (an embodiment of which is shown in FIG. 10e). 5. Overlaying the distance map image of the sleeve support shape onto the distance map image of the support structure model at a position corresponding to the longitudinal axis 1110 of the guide hole in the support structure model and adding support structure model material 1120 where the combined values of the distance map images exceed a threshold. An example of the original support structure model is shown in FIG. 11a. An example of the modified support structure model after adding the sleeve support shape is shown in FIG. 11b. 6. Where the distance map images of multiple sleeve support shapes overlap, adding support structure model material 1120 where the combined values of the distance map images exceed a threshold. An example of the support structure model material connecting two sleeve support shapes is shown in FIG. 11c. 7. Overlaying the image of the punch shape 1040 onto the distance map image of the support structure model at a position corresponding to the top of the guide hole in the support structure model and removing support structure model material at all points within the punch image. An example of the support structure model of FIG. 11b after removal of the punch material is shown in FIG. 11d. 8. Once all of the above steps have been completed for each of the guide holes, the support structure model image is converted to a 3D surface model. This process may be done using a marching cubes algorithm. 9. After that, a 3D surface model 1240 of the top surface of the sleeve support (FIG. 12a) is added again to the support structure model 3D surface model at a position corresponding to the top of the guide hole. This provides a clean and level top surface for the top of the guide hole where it interfaces with a drill guide. 10. Then a 3D surface model of the sleeve support space 1220 (FIG. 12b) is subtracted, to provide a hole for drilling and insertion of an implant. The sleeve support space shown in FIG. 12b also includes a portion 1210 to provide an interface between the final surgical template and the sleeve and to provide space for glue retention between the two. 11. Finally, a 3D surface of a glue tube 1230 (FIG. 12c) is subtracted so that the glue can be inserted in between the final surgical template and the sleeve in order to fix the sleeve to the template. 12. FIG. 13a shows all the components of FIGS. 12a-12c together in one image. FIG. 13b shows a collection of equivalent components used to form an anchor pin guide hole in the final surgical template. 13. In order to remove any material added in the above steps to the support structure model which affects the close fit with the teeth, the original 3D surface data of the patient's oral situation is subtracted from the support structure model 3D surface model. In one embodiment, a slightly enlarged 3D surface data of the patient's oral situation is subtracted from the support structure model 3D surface model in order to ensure a small degree of tolerance between the final produced surgical template and the patient's oral situation.

(73) In one embodiment of step 5 or step 6 above, if the combined distances of two points in the distance map images from their respective closest points on the respective surfaces is less than 2 mm, additional support material is added.

(74) This technique for generating guide holes in the support structure model is also applicable to the anchor pin guide holes used by the anchor pins to fix a surgical template to the patient's jawbone.

(75) Lateral Sleeve Openings

(76) In the preferred embodiment of the invention, lateral openings are provided in the support structure. The corresponding opening(s) in the produced dental splint allows the lateral insertion of guide sleeves and/or guide tools (i.e. tools with a component which fits the guide hole opening and provides support for a drill bit or other tool during the surgical procedure) into the guide hole(s). The lateral openings are formed in the support structure model by performing a Boolean subtraction of a box shape from the support structure. The subtraction provides a continuous opening from the guide hole to the external surface of the support structure. The opening begins at the coronal edge of the support structure model and runs parallel to the opening with a height greater, equal to, or shorter than the length of the guide hole. The width in the distal-mesial direction is equal to or slightly smaller than the diameter of the guide hole to provide a retention fit for components in the guide hole. Lateral openings may be provided at either the buccal or lingual side of the support structure, although not both/

(77) In another embodiment, the lateral openings are formed by adjusting the cut-off line to provide a gap in the support structure model at either the buccal or lingual side. In such an embodiment, the same dimensions as described above are used.

(78) Support Structure Model Undercut Removal

(79) In the preferred embodiment, the support structure model is modified to ensure that it can be easily fitted over the patient's dentition. As shown in FIGS. 14a and 14b, the supporting tooth 1400 is wider at the crown 1405 of the tooth before narrowing towards the neck 1406 and root of the tooth. A support structure model 1410 formed according to the above methods will have a curving shape which matches the shape of the tooth. Consequently, the opening of the support structure model at the cut-off point 1420 could be narrower than the widest point of the tooth. This will make it difficult if not impossible for the dentist to fit a surgical template corresponding to the support structure model without damaging the surgical template.

(80) In the preferred embodiment, the support structure model is modified to remove any part 1420 of the support structure model which forms an undercut. In one embodiment, this is achieved by: 1. Along the arc 410 of the distance map image, the widest point of the teeth of the patient is calculated. The height of this widest point is also determined on the panoramic maximum intensity projection of the distance map image. 2. Any part of the support structure model which is closer to the arc 410 and below the height of the widest point of the teeth is removed as shown in FIG. 14c.
Production of the Physical Surgical Template

(81) Finally, a physical surgical template (or dental splint) is produced in dependence on the virtual surgical template model. The physical surgical template may be manufactured using an additive manufacturing technique. The advantage of this technique is the speed with which the physical surgical template can be produced. Preferably, the physical surgical template is produced as a physical reproduction of the virtual surgical template model using stereolithography. Other additive manufacturing technologies that may be used include inkjet 3D printers or SLS printers. Alternatively, the physical reproduction of the virtual surgical template model may be milled from a block of material.