Multi-layer casting methods and devices
Described herein are methods for making highly accurate layered dental models from a cast of a subject's oral cavity (e.g., the upper or lower dental arch) that avoid shrinkage or deformation. The methods may include the steps of sequentially preparing the model-forming material, applying a layer of model-forming material to a cast, and curing the layer before applying the next layer. The model-forming material may include one or more stabilizers (e.g. thermal stabilizers). Dental models having multiple layers are also described.
1 . A method of making a layered dental model, comprising:
applying a first layer of model-forming material to a cast;
curing the first layer of model-forming material;
applying a second layer of model-forming material; and
curing the second layer of model forming material.
2 . The method of claim 1 , further comprising:
applying a third layer of model-forming material; and
curing the third layer of model forming material.
3 . The method of claim 1 , further comprising removing the dental model from the cast.
4 . The method of claim 1 , wherein the model-forming material comprises Epoxy.
5 . The method of claim 1 , wherein the step of applying the first layer of model-forming material comprises brushing the model forming material against the cast.
6 . The method of claim 1 , wherein the step of applying the first layer of model-forming material comprises spraying the model-forming material within the cast.
7 . The method of claim 1 , wherein the step of applying the first layer of model-forming material comprises pouring the model-forming material within the cast.
8 . The method of claim 1 , wherein the step of applying the first layer of model-forming material comprises applying the first layer of model-forming material so that the temperature of the first layer of model-forming material does not exceed 40° C. during curing at room temperature.
9 . The method of claim 1 , further comprises the step of preparing the model-forming material, and wherein the step of preparing the model-forming material comprises:
mixing an Epoxy resin with an Epoxy hardener.
10 . The method of claim 9 , wherein the step of preparing the model-forming material further comprises mixing the Epoxy resin with a stabilizer.
11 . The method of claim 10 , wherein the stabilizer comprises Al powder.
12 . The method of claim 1 , further comprising placing the cast into a casting chamber.
13 . The method of claim 1 further comprising annealing the dental model.
14 . A method of making a dental model comprising:
mixing Epoxy for a first layer;
applying the first layer of Epoxy to a cast by brushing at least a portion of the Epoxy on at least a portion of the cast and pouring at least a portion of the Epoxy into the cast;
curing the first layer of Epoxy;
mixing Epoxy for the second layer;
applying the second layer of Epoxy; and
curing the second layer of Epoxy.
15 . The method of claim 14 , further comprising:
mixing Epoxy for the second layer;
applying the third layer of Epoxy; and
curing the third layer of Epoxy.
16 . The method of claim 15 , wherein the second layer is cured for at least 10 minutes before apply the third layer of Epoxy.
17 . The method of claim 14 , further comprising annealing the dental model by baking the dental model at greater than about 40° C. for greater than about 2 hours.
18 . The method of claim 14 , further comprising including Al powder as part of the Epoxy in at least the first layer.
19 . A dental model comprising a plurality of solid layers formed from sequentially cured layers of Epoxy, wherein at least one layer includes a stabilizer.
20 . The dental model of claim 19 , wherein the stabilizer comprises Al powder.