Producing wrinkled dental aligner for dental treatment

1. A method for manufacturing a wrinkled dental aligner for a patient's tooth, comprising:

developing a first digital dental aligner model comprising outer surfaces and inner surfaces designed to approximately follow at least some contours of outer surfaces of a digital dental arch model of the patient's dental arch in a target position, the first model configured to apply a system of forces to elicit movement of one or more teeth in accordance with a treatment plan;

modifying the first model so as to create a second digital dental aligner model, the modifying comprising adding at least one predetermined wrinkle feature to the first digital dental aligner model, wherein the second model is configured to apply substantially the same system of forces to the teeth as the first model, and wherein the wrinkle feature is configured to reduce relaxation in a corresponding physical aligner after repeated use; and

producing a physical dental aligner that is a physical embodiment of the second digital dental aligner model, the physical dental aligner having the wrinkle feature in accordance with said second digital dental aligner model, the physical dental aligner comprising a shell defining tooth receiving cavities, the wrinkle feature comprising a corrugated structure formed in a portion of material of the physical dental aligner that is in contact with the patient's tooth as the aligner is worn by the patient, the wrinkle feature configured to reduce loss of tooth movement eliciting forces due to relaxation in the physical aligner after repeated use, and wherein the wrinkle feature is other than contours of outer and inner surfaces of the aligner shell that approximately follow contours of the outer surfaces of the digital dental arch model of the patient's dental arch.

2. The method of claim 1 , further comprising:

producing the physical dental aligner having the wrinkle feature by vacuum forming over a dental arch model of the patient, wherein at least one surface of the dental arch model includes features to produce the wrinkle feature on the physical dental aligner.

3. The method of claim 1 , further comprising:

producing the wrinkle feature on the physical dental aligner by

embedding a high-tension material under the surface of the physical dental aligner.

4. The method of claim 1 , further comprising:

producing the wrinkle feature on the physical dental aligner by cutting the surface of the physical dental aligner.

5. The method of claim 1 , further comprising:

producing the wrinkle feature on the physical dental aligner by etching the surface of the physical dental aligner by a thermal applier or a laser beam.

6. The method of claim 1 , further comprising:

fabricating a plurality of aligner components using CNC based manufacturing in accordance with the digital dental aligner model; and

producing the physical dental aligner having the wrinkle feature by assembling the aligner components.

7. The method of claim 6 , wherein the CNC based manufacturing includes one or more of milling, stereo lithography, laser machining, molding, and casting.

8. The method of claim 6 , further comprising:

producing physical features on the aligner components to permit the aligner components to be assembled into the physical dental aligner having at least one wrinkle feature.

9. The method of claim 1 , further comprising:

simulating the performance of the physical dental aligner under one or more stress conditions using the digital dental aligner model; and

optimizing one or more parameters of the wrinkle feature based on the simulated behavior.

10. The method of claim 9 , wherein optimizing one or more parameters of a wrinkle feature includes:

determining one or more of the locations of the wrinkles;

determining the orientations of the wrinkles;

determining the spacing between adjacent wrinkles;

determining the depths of the wrinkles; or

any combination thereof.

11. The method of claim 10 , wherein the wrinkle feature is oriented:

horizontal to the base line of the dental aligner;

vertical to the base line of the dental aligner; or

any combination thereof.

12. The method of claim 10 , wherein the wrinkle feature is oriented as a corrugated structure proximal to the base line of the dental aligner.

13. The method of claim 1 , further comprising:

developing the digital dental aligner model based on a digital dental arch model.

14. The method of claim 1 , further comprising:

segmenting the digital dental aligner model into a plurality of digital aligner components;

producing physical aligner components using Computer Numerical Control (CNC) based manufacturing in accordance with the digital aligner components; and

assembling the physical aligner components to form the wrinkled dental aligner.

15. A method for generating a wrinkled dental aligner for a patient's tooth, comprising:

generating a first digital dental aligner model specifying at least one feature of the patient's tooth and configured to apply a system of forces to elicit movement of one or more teeth in accordance with a treatment plan, the first digital dental aligner model comprising outer surfaces and inner surfaces designed to approximately follow contours of outer surfaces of a digital model of the patient's dental arch in a target position; and

modifying the first model so as to create a second digital dental aligner model, the modifying comprising adding at least one predetermined wrinkle feature to the first digital dental aligner model, the second model designed to apply substantially the same system of forces as the first model, and wherein the wrinkle feature comprises a corrugated structure formed proximal to a baseline and in a portion of material of the physical dental aligner that is in contact with the patient's tooth as the aligner is worn by the patient, and is selected to reduce loss of corrective force applied to the patient's teeth by a corresponding physical aligner after repeated use by the patient, wherein the wrinkle feature is other than contours of outer and inner surfaces of the aligner shell that approximately follow contours of the outer surfaces of the patients dental arch.

16. The method of claim 15 , further comprising:

determining one or more of the locations of the wrinkles;

determining the orientations of the wrinkles,

determining the spacing between adjacent wrinkles;

determining the depths of the wrinkles; or

any combination thereof.

17. The method of claim 16 , wherein the wrinkle feature is designed to be oriented:

horizontal to the base line of the dental aligner;

vertical to the base line of the dental aligner; or

any combination thereof.

18. The method of claim 16 , wherein the wrinkle feature is designed to be oriented as a corrugated structure proximal to the base line of the dental aligner.

19. The method of claim 15 , further comprising manufacturing the wrinkled dental aligner.