Abstract: A method for generating a 3D model for a restoration is operative in a computer having a display. The method begins by obtaining a 3D model of the preparation. The preparation model may be obtained by an operator using a 3D digitizer. A “margin” curve on the preparation model is then determined. The method then continues by selecting a given 3D restoration cap model from a set of such models, where the set includes cap models that vary by one or more characteristics such as type, age, sex and ethnicity. The restoration cap model has a cap edge curve. According to the invention, the method then continues by fitting the restoration cap model over the preparation model (on the computer display) so that a minimum distance between the restoration cap and the restoration model is greater than a given minimum material thickness. The restoration cap model is then reshaped or otherwise scaled as necessary so that the restoration cap edge curve is related to the margin curve in a predetermined manner.

Abstract: The present invention relates generally to mill blank constructions. According to the invention, a “smart blank” is pre-configured into a form that closely resembles a restoration being designed. The blank comprises a body adapted to be shaped by material removal into an artificial tooth part having buccal-lingual, mesial-distal and occlusal-cervical axes. In an illustrative embodiment, the body has at most one symmetric plane that is defined by a buccal-lingual-occlusal-cervical cross-section whose normal is along the mesial-distal axis. The blank also includes a holder for mounting the blank in a shaping apparatus. The smart blank provides more efficient milling and high yield.

Abstract: The present invention relates generally to mill blank constructions to facilitate the manufacture of dental restorations. A given mill blank is formed in a shape (i.e. with a given geometry) that has been predetermined to reduce material waste when the mill blank is machined into the final part. A set of two or more blanks each having such characteristics comprise a smart blank “library.” In one embodiment, a smart blank library includes a sufficient number of unique blanks such that, when the geometry of the designed restoration is known, the smart blank with a highest yield can be selected for use in milling the restoration. The “yield” of a given smart blank represents the amount of material of the smart blank that is actually used in the final restoration. Automated processes for smart blank inventory management and smart blank selection are also described.