Abstract: Methods and an apparatus for bending orthodontic wires are provided. An apparatus for bending an orthodontic wire can determine an optimal shape of a portion of an archwire to include a pair of nominal bends, apply an actual bend to the archwire at a location coinciding with the location of one of the pair of nominal bends, measure the actual bend applied, compare the actual bend to the nominal bend to determine an amount of deviation from that desired, determine corrective movements to substantially eliminate the deviation, iteratively reexecute such steps until the deviation is within a predefined tolerance, and recalculate a value of the other of the pair of nominal bends to compensate for any remaining deviation.

Abstract: A system to manufacture orthodontic appliances, program product, and associated methods are provided. An embodiment of a system can include a virtual orthodontic appliance design computer having orthodontic appliance design program product provided to design a virtual dimensional representation of an orthodontic appliance including bracket bodies and bracket pads, and a mold apparatus positioned to form each bracket body and bracket pad. The system also includes a data processing computer including computer-aided manufacturing program product provided to derive electrical discharge device control instructions including a virtual dimensional representation of a bracket slot in the bracket, and an electrical discharge machining apparatus. The electrical discharge machining apparatus can include a controller including control program product to derive a control signal carrying the electrical discharge device control instructions and an electrical discharge device.

Abstract: An apparatus for bending orthodontic wires has means for guiding and holding a wire. In order to prevent forces resulting from compressive or stretching strain during the bending process, one of these means does not apply any longitudinal forces onto the wire by design. In another implementation, the apparatus for bending orthodontic wires has a gimbal-mounted gripper for bending the wire. Furthermore, a method is disclosed for applying two bends at the same longitudinal wire location in two different directions.

Abstract: A method for applying a desired shape to an orthodontic archwire includes the steps of obtaining a numerical description of the desired shape of an orthodontic archwire, generating a description of the design of a fixture basing on the numerical description, manufacturing a fixture basing on this description of the design, constraining a wire into the fixture and applying an adequate treatment to the wire in order to cause it to adopt the shape dictated by the fixture.

Abstract: A set of customized orthodontic brackets are provided with slots that are arranged substantially parallel to the tooth surface. The archwire, in an as-manufactured condition, has a portion of substantial arcuate extent, which is canted relative to the occlusal plane. The brackets are designed on a computer as a combination of three-dimensional virtual objects comprising the virtual bracket bonding pad and a separate virtual bracket body retrieved from a library of virtual bracket bodies. The virtual brackets can be represented as a file containing digital shape data and exported to a rapid prototype fabrication device for fabrication of the bracket in wax or other material and casting the wax prototype in a suitable alloy. Other manufacturing techniques are also contemplated, including milling and laser sintering.