Customized fabrication of orthodontic retainers based on patient anatomy

Abstract

Dental retainer devices are provided. The dental retainer devices can be customized based on patient specific dental anatomy and dental treatment plans. Methods of making the dental retainer devices are also provided. The methods can included additive manufacturing. Methods are also provided for customization of a dental retainer device based on the patient specific anatomy. The methods for customization can include providing a dentist with different options for anterior teeth coverage, posterior teeth coverage, and palatal configurations for the dental retainer devices.

What is claimed is: 
     
         1 . A dental retainer device comprising:
 a unitary body formed of a retainer material, the unitary body having different thicknesses along its length, the unitary body defining multiple regions including:
 an anterior teeth region configured to hold a patient's anterior teeth within a pocket having lingual and occlusal sides; 
 a first posterior teeth region and a second posterior teeth region each configured to hold the patient's molars in a pocket having lingual and occlusal sides; and 
 a palatal region configured to extend between the first and second posterior teeth regions and adjacent to the patient's palate, wherein the palatal region is thicker than the occlusal side of the first and second posterior teeth regions; 
 wherein a top surface of the palatal region is smoother than a bottom surface of the palatal region, further wherein the bottom surface is configured to be worn adjacent to the patient's palate. 
   
     
     
         2 . The device of  claim 1 , further comprising an identifying code on one or more of: the bottom surface of the palatal region or a posterior edge of the palatal region. 
     
     
         3 . The device of  claim 1 , wherein the thickness of the palatal region increases between the first and second posterior teeth regions. 
     
     
         4 . The device of  claim 1 , wherein the palatal region comprises a plurality of strips extending between the first and second posterior regions. 
     
     
         5 . The device of  claim 1 , wherein the first and second posterior teeth regions each comprises a buccal surface configured to conform the patient's molars. 
     
     
         6 . The device of  claim 1 , wherein the first and second posterior teeth regions each comprises a buccal surface configured to extend at least 2 mm over the patient's gingiva when worn. 
     
     
         7 . The device of  claim 1 , wherein the unitary body includes an attachment structure configured to attach an elastic. 
     
     
         8 . The device of  claim 1 , wherein the unitary body includes a slot configured to attach an elastic. 
     
     
         9 . The device of  claim 1 , wherein the unitary body includes a mandibular advancement feature. 
     
     
         10 . The device of  claim 9 , wherein the mandibular advancement feature comprises a ramp surface extending from of the unitary body. 
     
     
         11 . The device of  claim 1 , wherein the unitary body includes a gingival support region. 
     
     
         12 . The device of  claim 1 , wherein the unitary body includes a plurality of ridges. 
     
     
         13 . The device of  claim 1 , further comprising a bias element attached to or integral with the unitary body. 
     
     
         14 . The device of  claim 1 , further comprising an interproximal support feature comprising one or more open spaces. 
     
     
         15 . The device of  claim 1 , further comprising an interproximal support feature comprising a second material, wherein the second material is less rigid than the retainer material. 
     
     
         16 . The device of  claim 1 , further comprising an interproximal support feature having a rigidity that is less rigid than the unitary body. 
     
     
         17 . The device of  claim 1 , wherein the retainer material has a Young's modulus of between about 0.01 and 5 GPa. 
     
     
         18 . The device of  claim 1 , wherein the retainer material comprises nylon. 
     
     
         19 . A dental retainer device comprising:
 a unitary body formed of a retainer material, the unitary body having different thicknesses along its length, the unitary body defining multiple regions including:
 an anterior teeth region configured to hold a patient's anterior teeth within a pocket having lingual and occlusal sides; 
 a first posterior teeth region and a second posterior teeth region each configured to hold the patient's molars in a pocket having lingual and occlusal sides; 
 a palatal region configured to extend between the first and second posterior teeth regions and adjacent to the patient's palate, wherein the palatal region is thicker than the occlusal side of the first and second posterior teeth regions, and the thickness of the palatal region increase between the first and second posterior teeth regions; 
 wherein a top surface of the palatal region is smoother than a bottom surface of the palatal region, further wherein the bottom surface is configured to be worn adjacent to the patient's palate; and 
 an identifying code on one or more of: the bottom surface of the palatal region or a posterior edge of the palatal region.