Method for manufacturing dental implant components
View Patent ↗A method for making a rapid prototype of a patient's mouth to be used in the design and fabrication of a dental prosthesis. The method takes an impression of a mouth including a first installation site having a dental implant installed in the first installation site and a gingival healing abutment having at least one informational marker attached to the dental implant. A stone model is prepared based on the impression. The model is scanned. The scan data is transferred to a CAD program. A three-dimensional model of the installation site is created in the CAD program. The at least one informational marker is determined to gather information for manufacturing the rapid prototype. Rapid prototype dimensional information is developed. The rapid prototype dimensional information is transferred to a rapid prototyping machine which fabricate a rapid prototype of the patient's dentition as well as a dental implant analog position.
1. A method of developing a physical model of dental features of a mouth of a patient, the physical model for use in making a final prosthesis that is to be coupled to a dental implant installed in the mouth of the patient, the method comprising:
scanning the mouth of the patient to develop scan data, the scanning including receiving information to identify a location of the dental implant installed in the mouth of the patient;
by use of the scan data, developing a three-dimensional computer model of the dental features of the mouth of the patient, the three-dimensional computer model including the location of the dental implant;
by use of the three-dimensional computer model, manufacturing the physical model of the dental features of the mouth so as to include an integral implant analog structure positioned in the physical model based on the location of the dental implant installed in the patient, the physical model being used to develop the final prosthesis by use of the integral implant analog structure, the integral implant analog structure being made of the same material as other parts of the manufactured physical model.
2. The method of claim 1 , wherein the integral implant analog structure includes a surface for receiving a custom abutment for use in creating the final prosthesis.
3. The method of claim 2 , wherein the final prosthesis is made of at least one of ceramic and porcelain.
4. The method of claim 2 , wherein the custom abutment is made of a metallic material.
5. The method of claim 2 , further comprising, by use of the three-dimensional computer model, developing and manufacturing the custom abutment.
6. The method of claim 1 , wherein the integral implant analog structure includes an anti-rotation structure having an orientation corresponding to an orientation of an anti-rotational structure of the dental implant installed in the mouth of the patient.
7. The method of claim 1 , wherein the manufacturing the physical model includes manufacturing the physical model including the integral implant analog structure via rapid prototyping.
8. The method of claim 1 , wherein the scanning includes scanning a healing abutment attached to the dental implant, the healing abutment including information markers that indicate the information regarding the dental implant.
9. The method of claim 1 , further comprising adding a compliant soft tissue element to the physical model in a region adjacent to the integral implant analog structure.
10. The method of claim 9 , wherein the compliant soft tissue element is made via rapid prototyping.
11. The method of claim 10 , wherein the material comprising the compliant soft tissue element is different from the material of the manufactured physical model.
12. A method of developing a physical model for use in making a final prosthesis that is to be coupled to a dental implant installed in a mouth of a patient, the method comprising:
scanning a stone model with dental features of the mouth of the patient to develop scan data, the stone model being created using an impression of the dental features of the mouth of the patient, the scanning including receiving information to identify a location of the dental implant;
by use of the scan data, developing a three-dimensional computer model of the dental features of the mouth of the patient, the three-dimensional computer model including the location of the dental implant; and
by use of the three-dimensional computer model including the location of the dental implant, manufacturing the physical model of the dental features of the mouth so as to include an integral implant analog structure positioned in the physical model based on the location of the dental implant installed in the mouth of the patient, the integral implant analog structure including a surface for receiving an abutment for use in creating the final prosthesis, the integral implant analog structure being made of the same material as other parts of the manufactured physical model.
13. The method of claim 12 , wherein the manufacturing of the physical model includes manufacturing the physical model via rapid prototyping.
14. The method of claim 12 , wherein the final prosthesis is a crown that is configured to be attached to the abutment.
15. The method of claim 12 , wherein the integral implant analog structure includes an anti-rotation structure having an orientation corresponding to an orientation of an anti-rotational structure of the dental implant installed in the mouth of the patient.
16. The method of claim 12 , further comprising adding a compliant soft tissue element to the physical model in a region adjacent to the integral implant analog structure.
17. The method of claim 16 , wherein the compliant soft tissue element is made via rapid prototyping.
18. The method of claim 17 , wherein the material comprising the compliant soft tissue element is different from the material of the manufactured physical model.
19. A method of affixing an implant analog in a physical model of dental features of a mouth of a patient for use in creating a patient-specific prosthesis, the method comprising:
selecting, in a three-dimensional virtual model of the dental features of the mouth of the patient, one of a plurality of implant analogs to be used in the physical model;
determining, in the three-dimensional virtual model of the dental features of the mouth of the patient, the location of the selected implant analog to be placed in the physical model, the selected implant analog being located at substantially the same location as a dental implant installed in the mouth of the patient;
developing implant-analog positional information based on the location of the selected implant analog in the three-dimensional virtual model;
based on the three-dimensional virtual model and the implant-analog positional information, manufacturing a physical model that replicates the dental features of the mouth, the physical model including an implant analog receptacle that is at least partially dictated by the selected one of the plurality of implant analogs, the implant analog receptacle configured to receive the selected implant analog; and
affixing the selected implant analog within the implant analog receptacle of the physical model, the opening having dimensions such that the selected implant analog is affixed in the implant analog receptacle having the upper surface of the selected implant analog located at substantially the same relative location as the upper surface of the dental implant installed in the mouth of the patient.
20. The method of claim 19 , wherein the implant analog includes an anti-rotation structure having an orientation corresponding to an orientation of an anti-rotational structure of the dental implant installed in the mouth of the patient.
21. The method of claim 19 , wherein the manufacturing includes rapid prototyping the physical model.
22. The method of claim 19 , further comprising adding a compliant soft tissue element to the physical model in a region adjacent to the implant analog receptacle.
23. The method of claim 22 , wherein the compliant soft tissue element is made via rapid prototyping.
24. The method of claim 23 , wherein the material comprising the compliant soft tissue element is different from the material of the manufactured physical model.
25. The method of claim 19 , further comprising:
prior to the determining, scanning the dental features in the mouth of the patient to develop scan data; and
by use of the scan data, developing the three-dimensional virtual model.
26. The method of claim 25 , further comprising prior to the scanning the dental features, installing the dental implant in the mouth of the patient.
27. The method of claim 26 , further comprising, prior to the scanning the dental features, attaching an attachment member to the installed dental implant, the attachment member including features for identifying the location of the installed dental implant during the scanning.
28. The method of claim 27 , wherein the scanned dental features include at least a portion of the attachment member.
29. The method of claim 1 , further comprising, by use of the three-dimensional computer model, developing the final prosthesis.
30. The method of claim 29 , wherein the final prosthesis includes an abutment.
31. The method of claim 30 , wherein the abutment is a custom abutment made from the three-dimensional computer model.
32. The method of claim 19 , further comprising, by use of the three-dimensional virtual model, developing the patient-specific prosthesis.
33. The method of claim 32 , wherein the patient-specific prosthesis includes an abutment.
34. The method of claim 33 , wherein the abutment is a custom abutment made from the three-dimensional virtual model.
35. The method of claim 1 , wherein the three-dimensional computer model includes a soft-tissue geometric contour surrounding the dental implant.
36. The method of claim 12 , wherein the three-dimensional computer model includes a soft-tissue geometric contour surrounding the dental implant.
37. The method of claim 19 , wherein the three-dimensional virtual model includes a soft-tissue geometric contour surrounding the dental implant.