Apparatus and methods of making denture devices
The present application describes a method for designing and manufacturing an implant-supported denture device for a patient. A method is described for designing a virtual denture and manufacturing an implant-supported functional fitting replica denture from the virtual denture. An apparatus comprising a functional fitting replica denture is prepared having denture teeth having a fit substantially similar to the final denture. The methods and apparatus described herein reduce the number of visits required to manufacture the final denture.
1. A method of making an implant-supported functional fitting replica denture device for a patient comprising
a. obtaining a physical model of an implant-supported denture device that comprises
a teeth region,
a gingival region, and
at least one hole through a thickness of the physical model that corresponds to a position and orientation of an implant of the patient;
b. removing a portion of the physical model comprising, removing a portion of the teeth region to form a gap in the physical mode;
c. selecting a plurality of denture teeth that corresponds to teeth in the portion of the teeth region removed from the physical model;
d. positioning the denture teeth into the gap of the physical model; and
e. substantially filling the gap with a formable material and securing the denture teeth in position in the gap with the formable material.
2. The method of claim 1 wherein the physical model further comprises at least one abutment interface surrounding the at least one hole on a surface of the physical model that is adjacent a patient's jaw when installed in the mouth of a patient.
3. The method of claim 1 , further comprising configuring the at least one hole with a diameter that can accommodate an implant insert for insertion within the hole through which an attachment means can pass.
4. The method of claim 1 , wherein the physical model of a denture is a unitary structure formed by a three-dimensional (3D) printing process.
5. The method of claim 1 , wherein the denture teeth positioned in the gap comprise at least two denture teeth selected from central incisors, lateral incisors, and cuspids.
6. The method of claim 1 , wherein the step of removing a portion of the physical model further comprises removing a portion of the gingival region and forming a gingiva indentation adjacent the gap.
7. The method of claim 1 , further comprising the step of forming a mold of the physical model prior to the step of removing at least a portion of the teeth region.
8. The method of claim 7 further comprising assembling the mold, the denture teeth and the physical model after the step of removing at least a portion of the physical model, wherein the step of filling the gap with the formable material further comprises substantially filling the gingiva indentation and replicating a portion of a patient's natural gingiva.
9. A method of making a denture device for a patient comprising
a. obtaining a physical model of an implant-supported denture device that comprises
a teeth region,
a gap in a portion of the teeth region that corresponds to at least a portion of
an anterior teeth region,
a gingival region, and
at least one hole that aligns with an implant location of the patient, and
b. selecting a plurality of anterior denture teeth that corresponds to the teeth region of the gap in the physical model;
c. positioning the denture teeth into the gap of the physical model; and
d. substantially filling the gap with a formable material and securing the denture teeth in position in the gap.
10. The method of claim 9 wherein the gap is between two posterior teeth regions.
11. The method of claim 9 wherein the anterior denture teeth positioned in the gap comprise at least two denture teeth selected from central incisors, lateral incisors, and cuspids.
12. The method of claim 9 wherein the physical model comprises a ridge adjacent the gap.
13. The method of claim 9 wherein the physical model comprises a gingival indentation adjacent the ridge.
14. The method of claim 10 wherein the step of substantially tilling the gap with formable material comprises filling the gingival indentation and forming a uniformly level surface between the formable material and the gingival region.
15. The method of claim 9 wherein the formable material comprises a hydroplastic or thermoplastic material.
16. The method of claim 9 wherein the formable material comprises a wax.
17. The method of claim 9 wherein the physical model is comprised of polymeric material that was shapeable into the physical model by an automated additive manufacturing process.
18. The method of claim 9 wherein the at least one hole that aligns with an implant location accommodates an attachment means.
19. The method of claim 9 wherein the denture device further comprises an attachment means.
20. The method of claim 9 wherein the denture device further comprises an attachment means comprising a screw.
21. The method of claim 9 wherein the denture device further comprises an attachment means comprising a denture clip.