IP Library Granted Patent US 12,390,960
Granted Patent B2
US 12,390,960 · App. 16/915,914 · Granted Aug 19, 2025

Mold with receiving element and separable features

Inventors: Rohit Tanugula (San Jose, CA); Dennis Te (San Jose, CA); Peter Webber (Lafayette, CA); Shiva P. Sambu (Milpitas, CA); Crystal Tjhia (Sunnyvale, CA)
Assignee: Align Technology, Inc.
B29C33/448A61C7/08B29C33/3835B29C33/50B29C51/34B33Y40/20G05B19/4093B29L2031/753B29L2031/757B33Y10/00B33Y80/00
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Quick Facts
Patent No.
US 12,390,960
App. No.
16/915,914
Granted
Aug 19, 2025
Kind
B2
Abstract

A method includes determining a first shape of a main body of a mold associated with a dental arch for a patient. The method further includes determining a second shape of a separable feature of the mold. The method further includes determining a third shape and configuration of a receiving element of the main body to receive the separable feature. The method further includes outputting instructions for fabricating the separable feature and the main body that includes the receiving element for receiving the separable feature.

Claims (31)

1. A method of manufacturing, the method comprising:

determining, by a processing device coupled to memory, a first shape of a main body of a mold associated with a dental arch for a patient, the main body corresponding to a plurality of teeth of the dental arch;

determining, by the processing device, a second shape of a separable feature of the mold;

determining, by the processing device, a third shape and configuration of a receiving element that comprises one or more holes formed in at least a portion of at least one of the plurality of teeth of the main body to receive the separable feature;

causing, by the processing device, fabrication of the separable feature that comprises one or more protrusions configured to insert into the one or more holes;

causing, by the processing device, fabrication of the main body that includes the receiving element that comprises the one or more holes for receiving the one or more protrusions of the separable feature, wherein the one or more protrusions of the separable feature insert into the main body via the one or more holes of the receiving element to cause the separable feature to extend above top surfaces of the plurality of teeth of the main body; and

causing, by the processing device, fabrication of a shell over the main body and the separable feature, wherein the shell is configured to be worn in a mouth of the patient.

2. The method of claim 1 , wherein the separable feature is attached to the main body via the receiving element.

3. The method of claim 1 , wherein the shell is formed over the main body and the separable feature via thermoforming or pressure forming the shell over the main body and the separable feature.

4. The method of claim 3 , wherein the shell is an orthodontic aligner, an orthodontic retainer, or an orthodontic splint for at least one of aligning, retaining, or positioning one or more teeth of the patient.

5. The method of claim 3 , wherein the separable feature is to generate a protrusion in the shell to facilitate application of forces via the shell to reposition teeth or jaw of the patient.

6. The method of claim 3 , wherein the shell and the separable feature are to be removed from the main body, wherein the separable feature is retained inside the shell responsive to the shell being removed from the main body, and wherein the separable feature is to be removed from the shell subsequent to the shell being removed from the main body.

7. The method of claim 1 , wherein the separable feature is mechanically affixed to the main body via insertion into the receiving element.

8. The method of claim 1 , wherein the separable feature is formed at an area of the dental arch corresponding to a retentive feature comprising at least one of the plurality of teeth that have an undercut or a negative inclination.

9. The method of claim 1 , wherein the main body of the mold is generated from a model based on an intraoral scan of the dental arch of the patient.

10. An orthodontic shell fabricated by the method of claim 1 , wherein the orthodontic shell comprises protrusions caused by the separable feature.

11. A non-transitory computer-readable medium comprising first instructions which, when executed by a processing device, cause the processing device to perform operations comprising:

determining a first shape of a main body of a mold associated with a dental arch for a patient, the main body corresponding to a plurality of teeth of the dental arch;

determining a second shape of a separable feature of the mold;

determining a third shape and configuration of a receiving element that comprises one or more holes formed in at least a portion of at least one of the plurality of teeth of the main body to receive the separable feature;

causing fabrication of the separable feature that comprises one or more protrusions configured to insert into the one or more holes;

causing fabrication of the main body that includes the receiving element that comprises the one or more holes for receiving the one or more protrusions of the separable feature, wherein the one or more protrusions of the separable feature insert into the main body via the one or more holes of the receiving element to cause the separable feature to extend above top surfaces of the plurality of teeth of the main body; and

causing fabrication of a shell over the main body and the separable feature, wherein the shell is configured to be worn in a mouth of the patient.

12. The non-transitory computer-readable medium of claim 11 , wherein the separable feature is attached to the main body via the receiving element.

13. The non-transitory computer-readable medium of claim 11 , wherein the shell is formed over the main body and the separable feature via thermoforming or pressure forming the shell over the main body and the separable feature.

14. The non-transitory computer-readable medium of claim 13 , wherein the shell is an orthodontic aligner, an orthodontic retainer, or an orthodontic splint for at least one of aligning, retaining, or positioning one or more teeth of the patient.

15. The non-transitory computer-readable medium of claim 13 , wherein the separable feature is to generate a protrusion in the shell to facilitate application of forces via the shell to reposition teeth or jaw of the patient.

16. The non-transitory computer-readable medium of claim 13 , wherein the shell and the separable feature are to be removed from the main body, wherein the separable feature is retained inside the shell responsive to the shell being removed from the main body, and wherein the separable feature is to be removed from the shell subsequent to the shell being removed from the main body.

17. The non-transitory computer-readable medium of claim 11 , wherein the separable feature is mechanically affixed to the main body via insertion into the receiving element.

18. The non-transitory computer-readable medium of claim 11 , wherein the separable feature is formed at an area of the dental arch corresponding to a retentive feature comprising at least one of the plurality of teeth that have an undercut or a negative inclination.

19. The non-transitory computer-readable medium of claim 11 , wherein the main body of the mold is generated from a model based on an intraoral scan of the dental arch of the patient.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 29, 2020
From: TANUGULA, ROHIT; TE, DENNIS; WEBBER, PETER; SAMBU, SHIVA P.; TJHIA, CRYSTAL
To: ALIGN TECHNOLOGY, INC.
Reel/Frame 053079/0212 →
Continuity (4)
Continuation 15914640 · Mar 7, 2018
Division 14716607 · May 19, 2015
Provisional Application 62001489 · May 21, 2014
Related Publication 20200331171A1 · Oct 22, 2020
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