US 11,654,005 B2
Methods of three-dimensional printing for fabricating a dental appliance
Md Abu Hasan, York, PA (US); and Dan Ammon, York, PA (US)
Assigned to DENTSPLY SIRONA INC., York, PA (US)
Filed by DENTSPLY SIRONA Inc., York, PA (US)
Filed on Nov. 4, 2020, as Appl. No. 17/88,643.
Application 17/088,643 is a continuation of application No. 16/402,440, filed on May 3, 2019, granted, now 10,856,957.
Claims priority of provisional application 62/666,396, filed on May 3, 2018.
Prior Publication US 2021/0113313 A1, Apr. 22, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. A61C 13/00 (2006.01); A61C 9/00 (2006.01); A61C 13/08 (2006.01); B33Y 80/00 (2015.01)
CPC A61C 13/0019 (2013.01) [A61C 9/0053 (2013.01); A61C 13/0004 (2013.01); A61C 13/0013 (2013.01); A61C 13/0018 (2013.01); A61C 13/08 (2013.01); B33Y 80/00 (2014.12)] 12 Claims
OG exemplary drawing
 
1. A method of fabricating a prosthetic denture base using a light-based three-dimensional (3D) printing apparatus, comprising the steps of:
(a) selecting a virtual 3D reference model of a prosthetic denture base, wherein the virtual 3D reference model of the prosthetic denture base includes:
i. a teeth-pockets facing side;
ii. a tissue facing side on the opposing side of the teeth-pockets facing side;
iii. a denture border extending around the peripheral edge of the prosthetic denture base, the denture border forming a boundary between the teeth-pockets facing side and tissue facing side; and
iv. an orienting reference plane aligned with a transverse or horizontal plane that is substantially aligned with the teeth-pockets facing side;
(b) creating at least one removable support structure about the virtual 3D reference model of the prosthetic denture base by:
i. positioning the virtual 3D reference model adjacent to a virtual build platform surface of the light-based 3D printing apparatus, wherein the tissue facing side of the virtual 3D reference model is placed proximal to the virtual build platform surface;
ii. manipulating a spatial orientation of the virtual 3D reference model by arranging the orienting reference plane of the virtual 3D reference model at an inclination angle between about 65 degrees to about 80 degrees relative to the virtual build platform surface, so that the anterior teeth-pockets are proximal to the virtual build platform surface while the posterior teeth-pockets are distal to the virtual build platform surface; and
iii. forming a revised 3D digital model having the at least one removable support structure and the virtual 3D reference model, wherein the at least one removable support structure connects the virtual 3D reference model to the virtual build platform surface;
(c) providing a reservoir of liquid photopolymerizable composition in contact with a build platform surface of the light-based three-dimensional printing apparatus;
(d) selecting, in software of a computer system that is in operative control of the light-based three-dimensional printing apparatus, printing process parameters to effectively photocure the liquid photopolymerizable composition in accordance with the revised 3D digital model; and
(e) instructing the light-based three-dimensional printing apparatus to print the prosthetic denture base and the at least one removable support structure based on the revised 3D digital model from the liquid photopolymerizable composition.