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Computer automated development of an orthodontic treatment plan and appliance - Align Technology, Inc.
United States Patent 8496474
Chishti, Muhammad (Washington, DC, US)
Freyburger, Brian (San Francisco, CA, US)
Wirth, Kelsey (Cambridge, MA, US)
Beers, Andrew (Redwood City, CA, US)
Wen, Huafeng (Redwood Shores, CA, US)
Benton, Phillips Alexander (Mountain View, CA, US)
Jones, Timothy N. (Mountain View, CA, US)
11/981641
A61C11/00
433/24, 433/213-214
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7578674 Methods for correcting tooth movements midcourse in treatment August, 2009 Chishti et al.
7377778 System for determining final position of teeth May, 2008 Chishti et al.
7320592 Defining tooth-moving appliances computationally January, 2008 Chishti et al.
7220122 Systems and methods for positioning teeth May, 2007 Chishti et al.
7134874 Computer automated development of an orthodontic treatment plan and appliance November, 2006 Chishti et al.
7037108 Methods for correcting tooth movements midcourse in treatment May, 2006 Chishti et al.
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6722880 Method and system for incrementally moving teeth 2004-04-20 Chishti et al.
6685469 System for determining final position of teeth 2004-02-03 Chishti et al.
6682346 Defining tooth-moving appliances computationally 2004-01-27 Chishti et al.
6629840 Method and system for incrementally moving teeth 2003-10-07 Chishti et al.
6626666 Method and system for incrementally moving teeth 2003-09-30 Chishti et al.
6554611 Method and system for incrementally moving teeth 2003-04-29 Chishti et al.
6471511 Defining tooth-moving appliances computationally 2002-10-29 Chishti et al.
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1. A method of providing a custom orthodontic appliance based on the anatomy of an individual patient wherein the appliance has a three dimensional surface having a shape matching the shape of at least a portion of a crown of at least one tooth of the individual patient, the method comprising: producing three dimensional digital data of shapes of crowns of a plurality of teeth of an individual-patient's teeth moved from an initial arrangement to an intermediate or final arrangement of the teeth; manufacturing a custom orthodontic shell appliance having a three dimensional surface having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient, based on the digital data, by a process that includes: manufacturing at least one intermediate object by depositing material, in accordance with the digital data, layer by layer in a plurality of layers, each layer containing a cross section having an edge defined by the digital data in the shape of at least one crown of a tooth of the individual patient, the layers being stacked so the edges form a three dimensional surface having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient; and, using the intermediate object to form the custom orthodontic appliance having a three dimensional surface matching the shape of at least a portion of the crown of at least one tooth of the individual patient wherein the shell appliance comprises cavities shaped to receive and resiliently reposition teeth.
2. The method of claim 1 wherein the manufacturing of the at least one intermediate object includes: depositing the material into the plurality of layers to form the cross sections of the intermediate object wherein the intermediate object is a mold having thereon the three dimensional surface having the shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient; and using the mold to form the custom orthodontic appliance having a three dimensional surface matching the shape of at least a portion of the crown of at least one tooth of the individual patient.
5. A method of providing a custom orthodontic appliance based on the anatomy of an individual patient wherein the appliance has a three dimensional surface having a shape matching the shape of at least a portion of a crown of at least one tooth of the individual patient, the method comprising: producing three dimensional digital data of shapes of crowns of a plurality of teeth of an individual patient's teeth moved from an initial arrangement to an intermediate arrangement of the teeth; manufacturing a custom orthodontic shell appliance having a three dimensional surface having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient, based on the digital data, by a process that includes depositing material, in accordance with the digital data, layer by layer into a plurality of layers to form cross sections of a pattern having the shape of at least a portion of one crown of a tooth of the individual patient, the layers being stacked so the edges form a three dimensional surface having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient; and, using the pattern to form the custom orthodontic shell appliance having a three dimensional surface matching the shape of at least a portion of the crown of at least one tooth of the individual patient, wherein the shell appliance comprises cavities shaped to receive and resiliently reposition teeth toward the intermediate arrangement.
6. The method of claim 5 wherein the depositing of material to form a pattern includes: depositing the material into the plurality of layers to form the cross sections of a pattern that is a mold having thereon the three dimensional surface having the shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient; and using the mold to form the custom orthodontic appliance having a three dimensional surface matching the shape of at least a portion of the crown of at least one tooth of the individual patient.
8. A method of providing a custom orthodontic appliance based on the anatomy of an individual patient wherein the appliance has a three dimensional surface having a shape matching the shape of at least a portion of a crown of at least one tooth of the individual patient, the method comprising: producing three dimensional digital data of shapes of crowns of a plurality of teeth of an individual patient's teeth moved from an initial arrangement to an intermediate arrangement of the teeth; manufacturing a custom orthodontic shell appliance having a three dimensional surface having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient, based on the digital data, by a process that includes depositing material using a rapid prototyping machine so as to form an intermediate object or pattern having a shape matching the shape of at least a portion of the crown of at least one tooth of the individual patient; and, using the intermediate object or pattern to form the custom orthodontic shell appliance having a three dimensional surface matching the shape of at least a portion of the crown of at least one tooth of the individual patient, wherein the shell appliance comprises cavities shaped to receive and resiliently reposition teeth toward the intermediate arrangement.
The path-generating program, whether using linear or non-linear interpolation, selects the treatment positions so that the tooth's treatment path has approximately equal lengths between each adjacent pair of treatment steps. The program also avoids treatment positions that force portions of a tooth to move with more than a given maximum velocity. FIG. 15C shows a tooth that is scheduled to move along a first path T1 from an initial position T11; to a final position T13, through an intermediate position T12, which lies closer to the final position T13. Another tooth is scheduled to move along a shorter path T2 from an initial position T21 to a final position T23; through an intermediate position T22, which is equidistant from the initial and final positions T21, T23. In this situation, the program may choose to insert a second intermediate position T14 along the first path T1 that is approximately equidistant from the initial position T11 and the intermediate position T12 and that is separated from these two positions by approximately the same distance that separates the intermediate position T12 from the final position T13.
After the configuration space has been defined, at step 128, path scheduling is performed between an initial state “sinit” and a final state “sfinal”. FIG. 8D depicts a flow chart for performing step 128 depicted in FIG. 8A. As illustrated in FIG. 8D, at step 128a, a set of states “W” is defined to initially contain only the initial state sinit. Next. at step 128b, the visibility function is invoked to determine if V(s, sfinal) is true for at least one state si in W. If the visibility function returns a false boolean value, at step 128c, the set of states “W” is replaced with the union of C(si) for all si in W. Steps 128b and 128c are repeated until V(si, sfinal) returns a true boolean value for any si belonging to W.
FIGS. 21A and 21B illustrate the use of the “level-of-detail” technique by the download software in the remote host. The software transfers the data in several groups, each of which adds detail incrementally for the rendered image of the teeth. The first group typically includes just enough data to render a rough polygon representation of the patient's teeth. For example, if a tooth is treated as a cube having six faces, the tooth can be rendered quickly as a diamond 2100 having six points 2102a-f, one lying in each face of the cube (FIG. 21A). The download software begins the download by delivering a few points for each tooth, which the interface program uses to render polygon representations of the teeth immediately.
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