Computer automated development of an orthodontic treatment plan and appliance

Abstract

A computer is used to create a plan for repositioning an orthodontic patient's teeth. The computer receives an initial digital data set representing the patient's teeth at their initial positions and a final digital data set representing the teeth at their final positions. The computer then uses the data sets to generate treatment paths along which the teeth will move from the initial positions to the final positions.

What is claimed is: 
     
         1 . A fabrication system for producing a plurality of orthodontic appliances configured to reposition a patient's teeth, the system comprising:
 one or more processors; and   memory comprising instructions that, when executed by the one or more processors, cause the system to:
 receive an initial digital data set representing the teeth in an initial arrangement; 
 generate a plurality of digital data sets representing a plurality of intermediate arrangements for repositioning the teeth from the initial arrangement towards a target arrangement; and 
 transmit the plurality of digital data sets to a rapid prototyping machine configured to directly fabricate a plurality of orthodontic appliances corresponding to the plurality of intermediate arrangements in response to receiving the plurality of digital data sets, 
   wherein the system is configured to generate the plurality of digital data sets at a stage of treatment prior to the patient wearing any of the plurality of orthodontic appliances.   
     
     
         2 . The system of  claim 1 , wherein the rapid prototyping machine comprises a stereolithography machine. 
     
     
         3 . The system of  claim 1 , wherein the rapid prototyping machine is configured to directly fabricate the plurality of orthodontic appliances by selectively hardening a liquid into a three-dimensional structure. 
     
     
         4 . The system of  claim 3 , wherein the three-dimensional structure is used directly as an orthodontic appliance. 
     
     
         5 . The system of  claim 3 , wherein the liquid is hardened layer by layer in a plurality of layers, each layer of the plurality of layers containing a cross section having an edge defined by a respective digital data set in a shape of at least one crown of the teeth, wherein the plurality of layers are stacked so the edges form a three-dimensional surface having a shape matching the shape of the at least one crown of the teeth. 
     
     
         6 . The system of  claim 1 , further comprising the rapid prototyping machine. 
     
     
         7 . The system of  claim 1 , wherein the plurality of orthodontic appliances comprises cavities with different geometries shaped to receive and reposition the teeth from the initial arrangement towards the target arrangement. 
     
     
         8 . The system of  claim 1 , wherein the system is configured to generate the plurality of digital data sets prior to fabricating any of the plurality of orthodontic appliances. 
     
     
         9 . The system of  claim 1 , wherein the instructions further cause the system to segment teeth of the initial digital data set in order to generate a plurality of individually manipulable tooth components. 
     
     
         10 . The system of  claim 9 , wherein the plurality of digital data sets is generated by repositioning at least one of the plurality of individually manipulable tooth components. 
     
     
         11 . A method for producing a plurality of orthodontic appliances configured to reposition a patient's teeth, the method comprising:
 receiving an initial digital data set representing the teeth in an initial arrangement;   generating a plurality of digital data sets representing a plurality of intermediate arrangements for repositioning the teeth from the initial arrangement towards a target arrangement; and   transmitting the plurality of digital data sets to a rapid prototyping machine configured to directly fabricate a plurality of orthodontic appliances corresponding to the plurality of intermediate arrangements in response to receiving the plurality of digital data sets,   wherein the plurality of digital data sets are generated at a stage of treatment prior to the patient wearing any of the plurality of orthodontic appliances.   
     
     
         12 . The method of  claim 11 , wherein the rapid prototyping machine comprises a stereolithography machine. 
     
     
         13 . The method of  claim 11 , wherein the rapid prototyping machine is configured to directly fabricate the plurality of orthodontic appliances by selectively hardening a liquid into a three-dimensional structure. 
     
     
         14 . The method of  claim 13 , wherein the three-dimensional structure is used directly as an orthodontic appliance. 
     
     
         15 . The method of  claim 13 , wherein the liquid is hardened layer by layer in a plurality of layers, each layer of the plurality of layers containing a cross section having an edge defined by a respective digital data set in a shape of at least one crown of the teeth, wherein the plurality of layers are stacked so the edges form a three-dimensional surface having a shape matching the shape of the at least one crown of the teeth. 
     
     
         16 . The method of  claim 11 , wherein the plurality of orthodontic appliances comprises cavities with different geometries shaped to receive and reposition the teeth from the initial arrangement towards the target arrangement. 
     
     
         17 . The method of  claim 11 , wherein the plurality of digital data sets are generated prior to fabricating any of the plurality of orthodontic appliances. 
     
     
         18 . The method of  claim 11 , further comprising segmenting teeth of the initial digital data set in order to generate a plurality of individually manipulable tooth components. 
     
     
         19 . The method of  claim 18 , wherein generating the plurality of digital data sets comprises repositioning at least one of the plurality of individually manipulable tooth components. 
     
     
         20 . A method for producing a plurality of orthodontic appliances configured to reposition a patient's teeth, the method comprising:
 receiving an initial digital data set representing the teeth in an initial arrangement;   generating a plurality of digital data sets representing a plurality of intermediate arrangements for repositioning the teeth from the initial arrangement towards a target arrangement; and   directly fabricating a plurality of orthodontic appliances corresponding to the plurality of intermediate arrangements by selectively hardening a liquid layer by layer to form each orthodontic appliance, based on the plurality of digital data sets,   wherein the plurality of orthodontic appliances are fabricated at a stage of treatment prior to the patient wearing any of the plurality of orthodontic appliances.