Parylene dental articles

1. A dental article comprising at least one segment defining a complex three-dimensional shape configured to follow contours of an oral anatomy, wherein the at least one segment comprises a core component, wherein the core component comprises a majority of parylene.

2. The dental article of claim 1 , wherein the core component is formed by depositing parylene from a chemical vapor deposition process over a model of an oral anatomy.

3. The dental article of claim 1 , wherein the core component comprises at least 95 percent by weight (wt. %) parylene.

4. The dental article of claim 1 , wherein the at least one segment comprises at least 95 wt. % parylene.

5. The dental article of claim 1 , wherein the at least one segment defines a segment thickness measured perpendicular from a surface of the at least one segment configured to contact the oral anatomy of a patient, wherein at least 80% of the segment thickness consists of the core component.

6. The dental article of claim 1 , wherein the core component defines a core thickness, wherein the core thickness defines a thickness variability of less than about ±5% across the entire core component.

7. The dental article of claim 1 , wherein the at least one segment further comprises at least one inorganic coating on the core component.

8. The dental article of claim 7 , wherein the at least one inorganic coating comprises a metal oxide chosen from silver oxide, zinc oxide, copper oxide, titanium oxide, aluminum oxide, and alloys thereof.

9. The dental article of claim 8 , wherein the metal oxide is chosen from silver doped zinc oxide, silver doped and aluminum doped zinc oxide, silver doped titanium oxide, aluminum doped zinc oxide, titanium oxide, and silver doped and copper doped zinc oxide.

10. The dental article of claim 1 , wherein the at least one segment further comprises at least polymeric hardcoat on the core component.

11. The dental article of claim 1 , wherein the complex three-dimensional shape is configured to follow contours of the oral anatomy of at least one tooth.

12. The dental article of claim 1 , further comprising a dental component attached to the at least one segment, wherein the dental component comprises a coating layer comprising parylene that encapsulates the dental component.

13. The dental article of claim 1 further comprising a dental component attached to the at least one segment, wherein a coating layer comprising parylene is integrally formed with the core component.

14. The dental article of claim 12 , wherein the dental component comprises a portion of a palatal expander or a dental tray aligner.

15. A method comprising:

forming a three-dimensional model of an oral anatomy of a patient;

forming a dental article comprising at least one segment defining a complex three-dimensional shape configured to follow contours of the oral anatomy, wherein forming the at least one segment comprises:

depositing a layer comprising parylene on the model, wherein the layer comprises a majority of parylene, and

using the layer comprising parylene to form a core component of the at least one segment.

16. The method of claim 15 , wherein forming a dental article further comprises:

after depositing the layer comprising parylene on the model, trimming the layer to a selected shape to form the core component; and

separating the core component from the model.

17. The method of claim 15 , wherein depositing a layer comprising parylene on the model comprises chemical vapor depositing the layer comprising parylene.

18. The method of claim 15 , wherein forming the dental article comprises forming a dental tray aligner, a night guard, a dental attachment, a retainer, a palatal expander, or a mouth guard.

19. The method of claim 15 , further comprising coating the core component with an inorganic material or a polymeric hardcoat, wherein the inorganic material comprises at least one of a metal, a metal alloy, a metal oxide, a metal salt, a ceramic, a glass, or a mineral.

20. A method comprising:

receiving, by a computing device, a digital representation of a three-dimensional (3D) oral anatomy of a patient, the oral anatomy providing initial positions of one or more teeth of the patient;

determining, by the computing device, dimensions and shapes for a dental article for the patient, wherein the dental article comprises at least one segment configured to at least partially surround a plurality of teeth to define complex 3D shape configured to follow contours of the oral anatomy, wherein the dimensions and shapes of the dental article are configured to reposition the one or more teeth of the patient from their initial positions to adjusted positions when the dental article is worn by the patient;

forming a 3D model of an oral anatomy based on the dimensions and shapes for the dental article; and

forming the dental article, wherein forming the at least one segment of the dental article comprises:

depositing a layer comprising parylene on the 3D model, wherein the layer comprises a majority of parylene, and

trimming the layer comprising parylene to a selected shape to form a core component of the at least one segment.