System and method for manufacturing a dental prosthesis and a dental prosthesis manufactured thereby
A dental prosthesis is made by externally machining successive layers of wax, each of which is formed on a previous prosthesis layer and/or on a coping. Each wax layer is used to form a mold in situ over the previous prosthesis layer/coping, and the appropriate prosthesis material is cast or otherwise molded to conform to the wax layer by the mold.
1. A method for manufacturing a dental prosthesis, comprising:
generating a three-dimensional virtual model of the dental prosthesis comprising a first virtual prosthesis layer including a first virtual external surface and a second virtual prosthesis layer including a first virtual internal surface, the first virtual internal surface being substantially complementary to the first virtual external surface;
producing a first wax model, corresponding to the first virtual prosthesis layer, the first wax model being produced by material operations to form a first external surface of the first wax model that corresponds to the first virtual external surface, the material operations being based on the three-dimensional virtual model;
producing a first prosthesis layer using the first wax model, the first prosthesis layer corresponding to the first virtual prosthesis layer and having a first external prosthesis surface corresponding to the first virtual external surface;
producing a second wax model, corresponding to the second virtual prosthesis layer, the second wax model being produced by material operations, wherein the material operations modify wax disposed on the first prosthesis layer to form a first internal surface of the second wax model that corresponds to the first virtual internal surface, the material operations being based on the three-dimensional virtual model; and
producing the dental prosthesis based on the first wax model and the second wax model.
2. The method according to claim 1 , wherein producing the second wax model comprises depositing wax on the first prosthesis layer.
3. The method according to claim 1 , wherein the second virtual prosthesis layer includes a second virtual external surface and producing the second wax model includes producing by material operations a second external surface of the second wax model that corresponds to the second virtual external surface.
4. The method according to claim 1 , wherein the dental prosthesis is a multi-layered bridge prosthesis, wherein the first and second wax models form a composite wax model of the dental prosthesis substantially corresponding to the three-dimensional virtual model.
5. The method according to claim 1 , wherein the dental prosthesis is a bridge prosthesis and the first virtual prosthesis layer includes second and third virtual internal surfaces, the second and third virtual internal surfaces substantially complementary to a corresponding external surface of a first and a second coping.
6. The method according to claim 1 , wherein the dental prosthesis is a multi-layered bridge prosthesis, wherein the set of first and second wax models each comprises a wax model of a respective layer of the dental prosthesis substantially corresponding to virtual prosthesis layers created in the three-dimensional virtual model.
7. The method according to claim 1 , wherein generating the three-dimensional virtual model of the dental prosthesis comprises providing a three-dimensional digital data relating to the patient's dentition, the three-dimensional digital data including data representative of surface topology of a preparation and its surroundings.
8. The method according to claim 7 , wherein the material operations are material removal operations.
9. The method according to claim 8 , wherein three-dimensional digital data is generated using an optical scanner and the optical scanner comprises a probe for determining a three-dimensional structure by focusing of an array of light beams.
10. The method according to claim 7 , wherein the three-dimensional data is derived from intraoral scanning performed directly on an intraoral cavity comprising the preparation.
11. The method according to claim 1 , wherein producing the dental prosthesis includes producing a dental prosthesis on a first coping.
12. A system for manufacturing a dental prosthesis, comprising:
a processor; and
memory comprising instructions that when executed by the processor, cause the system to:
generate a three-dimensional virtual model of the dental prosthesis comprising a first virtual prosthesis layer including a first virtual external surface and a second virtual prosthesis layer including a first virtual internal surface, the first virtual internal surface being substantially complementary to the first virtual external surface;
produce a first wax model, corresponding to the first virtual prosthesis layer, the first wax model being produced by material operations to form a first external surface of the first wax model that corresponds to the first virtual external surface, the material operations being based on the three-dimensional virtual model;
produce a first prosthesis layer using the first wax model, the first prosthesis layer corresponding to the first virtual prosthesis layer and having a first external prosthesis surface corresponding to the first virtual external surface;
produce a second wax model, corresponding to the second virtual prosthesis layer, the second wax model being produced by material operations, wherein the material operations modify wax disposed on the first prosthesis layer to form a first internal surface of the second wax model that corresponds to the first virtual internal surface, the material operations being based on the three-dimensional virtual model; and
produce the dental prosthesis based on the first wax model and the second wax model.
13. The system according to claim 12 , wherein producing the second wax model comprises depositing wax on the first prosthesis layer.
14. The system according to claim 13 , wherein generating the three-dimensional virtual model of the dental prosthesis comprises receiving a three-dimensional digital data relating to the patient's dentition, the three-dimensional digital data including data representative of surface topology of a preparation and its surroundings.
15. The system according to claim 14 , wherein the three-dimensional data is derived from intraoral scanning performed directly on an intraoral cavity comprising the preparation.
16. The system according to claim 12 , wherein the dental prosthesis is a multi-layered crown prosthesis, wherein the first and second wax models comprises a wax model of the first and second layer of the prosthesis substantially corresponding to first and second virtual prosthesis layers generated in the three-dimensional virtual model.
17. The system according to claim 12 , wherein the dental prosthesis is a multi-layered bridge prosthesis, wherein the first and second wax models form a composite wax model of the dental prosthesis substantially corresponding to the three-dimensional virtual model.
18. The system according to claim 17 , wherein the dental prosthesis is a bridge prosthesis and the first virtual prosthesis layer includes second and third virtual internal surfaces, the second and third virtual internal surfaces substantially complementary to a corresponding external surface of a first and a second coping.
19. The system according to claim 12 , wherein the dental prosthesis is a multi-layered bridge prosthesis, wherein the set of first and second wax models each comprises a wax model of a respective layer of the dental prosthesis substantially corresponding to virtual prosthesis layers created in the three-dimensional virtual model.
20. The system according to claim 14 , wherein the three-dimensional digital data is generated using an optical scanner.