Computer aided design matrix for the manufacture of dental devices

Abstract

Disclosed herein are methods of manufacturing a dental device, the method comprising: obtaining a set of clinical options for the dental device from a health care provider; creating a first data set from the set of clinical options; communicating the data set to a computer aided design (CAD) software; preparing a digital design for the dental device using the CAD software; communicating the digital design to an automated milling apparatus; and automatedly milling a block of polymer to obtain the dental device. Also disclosed are dental devices manufactured by the above method. Further disclosed are methods of treating or ameliorating apnea jaw-related disorder in a patient, the method comprising obtaining a dental device manufactured by the above method and positioning the dental device over the dentition prior to sleep, whereby the mandible is advanced forward relative to the maxilla, thereby ameliorating the symptoms of sleep apnea or the jaw-related disorder.

What is claimed is: 
     
         1 . A method of manufacturing a kit, the kit comprising a set of mandibular advancement devices, the method comprising:
 a. preparing a three-dimensional electronic model of the patient's dentition;   b. converting the electronic model to a data set;   c. obtaining a set of clinical options, i.e., a prescription, from a health care provider (HCP) for the treatment of the patient,   d. incorporating within a computer-aided design (CAD) software the data set and the set of clinical options;   e. automatedly manufacturing a dental appliance, having the set of clinical options, in accordance with the appliance data set;
 wherein:
 the set of mandibular advancement devices comprise at least one upper and at least one lower splint; 
 each upper and each lower splint independently comprises a fin, or a post for a fin to attach thereto; 
 each upper fin or post is located at a distance UD from the back of the upper splint, and each lower fin or post is located at a distance LD from the back of the lower splint; 
 the distances UD and LD are independently unchangeable; 
 
   f. providing a first spacer and a second spacer, each spacer having a thickness, and each spacer having a contact surface;
 wherein:
 each spacer connects by a locking mechanism to one of the upper or lower fin, or one of the upper or lower post; 
 the thickness of the first spacer is different than the thickness of the second spacer; 
 when added, the spacer affords a rake angle of between about 20° to about 80°, between about 80° to about 100°, or between about 100° to about 160°. 
 
   
     
     
         2 . The device of  claim 1 , wherein the upper and lower splints are designed digitally and manufactured according to the digital design. 
     
     
         3 . The device of  claim 1 , wherein each upper fin comprises a front surface and each spacer on a lower post comprises a back surface, wherein when the upper and lower splints are worn by a patient, the front surface of the upper fin contacts the back surface of the lower spacer along a contact surface; or 
     
     
         4 . The device of  claim 1 , wherein each spacer on an upper post comprises a front surface and each lower fin comprises a back surface, wherein when the upper and lower splints are worn by a patient, the front surface of the upper post contacts the back surface of the lower fin along a contact surface. 
     
     
         5 . The device of  claim 1 , wherein the shape of each or spacer is independently selected from a predesigned digital library. 
     
     
         6 . The device of  claim 1 , wherein the spacer comprises a locking mechanism. 
     
     
         7 . The device of  claim 6 , wherein the locking mechanism is a friction lock mechanism or a key-tab mechanism. 
     
     
         8 . The device of  claim 1 , wherein the set of clinical options comprises two or more clinical options selected from the group consisting of titration mechanisms, titration accessories, splint design, retention mechanisms, splint material, and fin or strap design or sleeve. 
     
     
         9 . The device of  claim 8 , wherein the titration mechanism is selected from the group consisting of microtitration series, jack screw titration, Herbst hinge titration, anterior hinge titration, strap titration, and mechanical hook. 
     
     
         10 . The device of  claim 8 , wherein the splint material option is selected from the group consisting of standard polymethylmethacrylate (PMMA), lined PMMA, high-strength polyetheretherketone (PEEK), polymer produced from polyoxymethylene and acetal copolymers (Duracetal®), glycol modified polyethylene terephthalate (PETg), and a physiologically compatible, water insoluble, non-maleable polymer. 
     
     
         11 . A kit manufactured by the method of  claim 1 . 
     
     
         12 . A kit comprising:
 a) a set of mandibular advancement devices comprising at least one upper and at least one lower splint;   each upper and each lower splint independently comprises a fin, or a post for a fin to attach thereto;   each upper fin or post is located at a distance UD from the back of the upper splint, and each lower fin or post is located at a distance LD from the back of the lower splint;   the distances UD and LD are independently unchangeable; and   b) at plurality of spacers, each spacer having a thickness, and each spacer having a contact surface; wherein:   each spacer connects by a locking mechanism to one of the upper or lower fin, or one of the upper or lower post;   the thickness of each spacer is different than the thickness of any other spacer of the plurality of spacers;   when added, the spacer affords a rake angle of between about 20° to about 80°, between about 80° to about 100°, or between about 100° to about 160°.