Method and apparatus for preparing removable dental prosthesis

1. A method for manufacturing a removable dental prosthesis using a dental impression tray assembly, three-dimensional (3D) scanner, 3D design software, and a 3D printer, the method comprising:

receiving dental impressions of a patient obtained using the dental impression tray assembly, the dental impressions including a bite registration and at least a mandibular impression or a maxillary impression;

receiving information related to the patient's jaw relations obtained using the dental impression tray assembly, the jaw relations including a vertical dimension and a centric relation;

receiving aesthetic figures including a teeth shade, a gum shade, or a lip length;

scanning the received dental impressions with the 3D scanner to provide data representative of an edentulous shape of the patient;

generating a 3D model of the dental prosthesis by incorporating the received information using the 3D design software;

displaying the generated 3D model on a display; and

3D printing the dental prosthesis using the 3D printer according to the 3D model,

wherein the dental impression tray assembly comprises:

an upper tray configured to receive impression material for taking a first impression of the patient's gum and sized to be inserted into the patient's mouth; and

a lower tray comprising:

a first piece configured to receive impression material for taking a second impression of the patient's gum and sized to be inserted into the patient's mouth, wherein the first piece is curved at about a central portion to form a right end portion and a left end portion; and

a pair of second pieces detachably coupled to the first piece, a right piece of the pair of second pieces coupled to the right end portion of the first piece and a left piece of the pair of second pieces coupled to the left end portion of the first piece.

2. The method of claim 1 , wherein the aesthetic figures further include at least a teeth size or midline that are incorporated into the 3D model.

3. The method of claim 1 , further comprising incorporating at least one of edentulous borders, a teeth set-up, or retention elements into the 3D model using the 3D design software.

4. The method of claim 1 , further comprising providing application software executable on a computer to at least the dentist or the patient, allowing at least the dentist or the patient to modify or adjust the 3D model using the application software.

5. The method of claim 1 , further comprising separating a gum portion and a teeth portion of the 3D model, and 3D printing the gum portion and the teeth portion separately.

6. The method of claim 1 , further comprising 3D printing the dental prosthesis by a ink-jet printing method, a digital light processing method, or a sterolithography method in which photo-curable compositions for the dental prosthesis are used.

7. The method of claim 6 , wherein the photo-curable compositions comprise at least one of mono and multifunctional methacrylates, aliphatic urethane methacrylates, silica powder, poly(methyl methacrylate) beads, photo-initiator, stabilizer, or pigment.

8. The method of claim 6 , wherein the photo-curable compositions comprise light-curable viscous mixtures comprising a poly(methyl methacrylate)/methyl methacrylate mixture, difunctional bisphenol A dimethacrylate, multifunctional methacrylate, urethane dimethacrylate, surface modified silica-based fine particles, a light-photo-polymerization initiator, a colorant, and at least one type of stabilizer.

9. The method of claim 1 , wherein:

the dental impression, the vertical dimension, the centric relation, the teeth shade, the gum shade, and the lip length are obtained during the patient's single visit to a dentist or dental professional; and

the aesthetic figures are incorporated into the 3D-printed dental prosthesis.

10. The method of claim 1 , wherein the upper tray comprises:

a third piece configured to measure the jaw relations of the patient's mouth along with the first piece of the lower tray,

wherein the third piece is sized to cover the patient's upper anterior gum and has a front portion and a rear portion.

11. The method of claim 10 , wherein:

the upper tray further comprises a fourth piece configured to be detachably coupled to the rear portion of the third piece;

the first impression is taken by inserting the third piece into the patient's mouth with the fourth piece attached;

the fourth piece is detached from the third piece after the first impression is obtained; and

the third piece retaining the first impression and the first piece of the lower tray retaining the second impression are inserted together into the mouth to determine the jaw relations.

12. The method of claim 11 , wherein the fourth piece of the upper tray is sized to cover a distal portion or a remaining portion of the patient's upper gum when attached to the third piece.

13. The method of claim 1 , wherein:

the dental impression tray assembly further comprises an intra-oral tracer that is configured to be detachably coupled to the first piece of the lower tray; and

the intra-oral tracer is inserted into the mouth to be placed between the upper tray and the first piece of the lower tray and to measure a vertical dimension and a centric relation.

14. The method of claim 13 , wherein:

the dental impression tray assembly further comprises a dental tracing apparatus comprising three layers, one of the three layers being removed to expose an adhesive surface of another one of the three layers such that the dental tracing apparatus is attached to a surface of the upper tray via the adhesive surface; and

the centric relation is recorded using the dental tracing apparatus.

15. The method of claim 14 , wherein:

the intra-oral tracer comprises an adjusting member that is inserted through an adjusting member receiving portion formed at a middle portion of the intra-oral tracer;

the centric relation is recorded on the dental tracing apparatus according to movement of the adjusting member that is in contact with the dental tracing apparatus in the patient's mouth; and

the adjusting member is raised or lowered to determine the vertical dimension and to adjust a size of the gap for receiving the bite registration material.

16. A system for manufacturing a removable dental prosthesis, the system comprising:

a three-dimensional (3D) scanner configured to scan dental impressions including a bite registration and at least a mandibular impression or a maxillary impression of a patient taken with a dental impression tray assembly to provide data representative of an edentulous shape of the patient;

a controller configured to:

receive the data from the 3D scanner;

receive information related to the patient's jaw relations obtained using the dental impression tray assembly, the jaw relations including a vertical dimension and a centric relation;

receive aesthetic figures including a teeth shade, a gum shade, or a lip length; and

generate a 3D model of the dental prosthesis based on the data received from the 3D scanner and the received information using 3D design software;

a display configured to display the generated 3D model and an application executed for customizing the 3D model; and

a 3D printer configured to 3D print the dental prosthesis according to the 3D model,

wherein the dental impression tray assembly comprises:

an upper tray configured to receive impression material for taking a first impression of the patient's gum and sized to be inserted into the patient's mouth; and

a lower tray comprising:

a first piece configured to receive impression material for taking a second impression of the patient's gum and sized to be inserted into the patient's mouth, wherein the first piece is curved at about a central portion to form a right end portion and a left end portion; and

a pair of second pieces detachably coupled to the first piece, a right piece of the pair of second pieces coupled to the right end portion of the first piece and a left piece of the pair of second pieces coupled to the left end portion of the first piece.

17. The system of claim 16 , wherein the 3D printer is further configured to 3D print the dental prosthesis by a ink-jet printing method, a digital light processing method, or a stereolithography method in which photo-curable compositions are used.

18. The system of claim 17 , wherein the photo-curable compositions comprise at least one of mono and multifunctional methacrylates, aliphatic urethane methacrylates, silica powder, poly(methyl methacrylate) beads, photo-initiator, stabilizer, or pigment.

19. The system of claim 17 , wherein the photo-curable compositions comprise light-curable viscous mixtures comprising difunctional bisphenol A dimethacrylate, multifunctional methacrylate, urethane dimethacrylate, surface modified silica-based fine particles, a light-photo-polymerization initiator, a colorant, and at least one type of stabilizer.

20. The system of claim 16 , wherein the dental impression tray assembly further comprises:

an intra-oral tracer that is configured to be detachably coupled to the first piece of the lower tray, the intra-oral tracer comprising an edge portion that is inserted into a receiving portion of the first piece.

21. The system of claim 16 , wherein:

the controller is further configured to separate a gum portion and a teeth portion of the 3D model; and

the 3D printer is further configured to 3D print the gum portion and the teeth portion separately.