Abstract: A mold includes a first section, a second section, and a weakened region that joins the first section to the second section. The weakened region is breakable, deflectable, or deformable in response to a first threshold force to enable the first section to be removed from a shell independently of the second section after the shell is formed over the mold. The first threshold force is less than a second threshold force that would damage or permanently deform the shell. The first section is a first mold of at least a portion of one or more first teeth of a dental arch and the second section is a second mold of at least a portion of one or more second teeth of the dental arch.

Abstract: A dental attachment placement device comprises a plurality of articulated registration elements shaped for placement on a plurality of teeth, which can facilitate placement, accommodate tooth movement, and improve alignment of the registration elements with the teeth, so as to accurately position an attachment for placement. The plurality of registration elements may comprise one or more attachment supports and one or more retention supports extending from the plurality of registration elements. A dental attachment can be removably coupled to the attachment support. The plurality of registration elements and attachment supports may be located on opposing sides of one or more teeth in order to maintain placement prior to adhering the attachment to the tooth. In some embodiments, each of the plurality of registration elements comprises a tooth registration surface shaped to engage the tooth with a specific position and orientation for accurate positioning of the attachment.

Abstract: Methods and systems for forming dental attachment formation apparatuses. Methods may include creating a virtual dental attachment formation apparatus including a body having a surface shaped to conform to contours of a virtual model of a patient's dentition, a well in the body that is shaped to receive a dental attachment, and a light path directed through the body to the well. A physical dental attachment formation apparatus may be manufactured based on the virtual dental attachment formation apparatus. At least a portion of the body of the physical dental attachment formation apparatus may be made of a light transmissive material. The physical dental attachment formation apparatus may include an opaque portion arranged to keep light from illuminating another portion of the body other than the well.

Abstract: Strategies that reduce shrinkage and ultimately warping of parts that are directly fabricated from photopolymer resins. This increases the accuracy of directly fabricated parts, which is essential for patient specific applications. Implementing these strategies can reduce the need for directly fabricated parts to have supporting structures, which can reduce pre-processing and post-processing steps and facilitate an easier route for production level scale of additive manufacturing.

Abstract: A support is coupled to an appliance to decrease warpage. The support may comprise a plurality of extensions coupled to the appliance to decrease warpage. The extensions can be coupled to the appliance at one or more of many locations, such as on an occlusal surface, a wall, an edge or an interior of the appliance. In some embodiments, the extensions are coupled to walls of the appliance such as a buccal wall and a lingual wall, and the extensions can be coupled to the walls of the appliance near edges of the walls, such as a gingivally facing edges of the walls that are oriented toward the gingiva when the appliance is worn.

Abstract: Strategies that reduce shrinkage and ultimately warping of parts that are directly fabricated from photopolymer resins. This increases the accuracy of directly fabricated parts, which is essential for patient specific applications. Implementing these strategies can reduce the need for directly fabricated parts to have supporting structures, which can reduce pre-processing and post-processing steps and facilitate an easier route for production level scale of additive manufacturing.

Abstract: Methods and systems for digitally designing a plurality of aligners are provided. In some embodiments, a method includes receiving an intraoral scan of the patient's teeth, and generating 3D dental model of the patient's teeth using the intraoral scan. The method can include identifying a movement path to move the patient's teeth from an initial arrangement toward a target arrangement through a plurality of intermediate arrangements in accordance with a treatment plan. The method can also include identifying one or more appliance features of at least one aligner, the one or more appliance features including one or more feature regions having one or more feature thicknesses. The method can further include instructing an additive manufacturing machine to directly fabricate the at least one aligner in a layer-by-layer fashion.

Abstract: Methods and apparatuses for attaching one or more dental attachments to a dentition. Methods may include placing an attachment placement apparatus on the dentition such that contoured surfaces of the attachment placement apparatus are aligned with correspondingly shaped tooth surfaces of the dentition. A body of the attachment placement apparatus may position the dental attachment(s) against specified location(s) on one or more teeth of the dentition. The dental attachment(s) may be coupled to supports that extend from the body. The supports may include breakable regions configured to be broken to facilitate removal of a corresponding dental attachment from the body. The supports may position the dental attachment(s) within corresponding aperture(s) of the attachment placement apparatus. The dental attachment(s) may be secured at the specified location(s) on the teeth.

Abstract: Dental attachment placement apparatuses and related systems. An apparatus may include a body having attachments. The attachments, when worn at specified locations on the patient's dentition, may engage with one or more aligners to direct repositioning forces from the aligner(s) to the patient's dentition. The body of the apparatus may have contoured surfaces shaped in accordance with corresponding surfaces of the patient's teeth. The apparatus may also include supports extending from body and that support a corresponding attachment entirely within a corresponding aperture of the apparatus. The supports may include breakable regions to facilitate removal of the attachments from the body.

Abstract: A support is coupled to an appliance to decrease warpage. The support may comprise a plurality of extensions coupled to the appliance to decrease warpage. The extensions can be coupled to the appliance at one or more of many locations, such as on an occlusal surface, a wall, an edge or an interior of the appliance. In some embodiments, the extensions are coupled to walls of the appliance such as a buccal wall and a lingual wall, and the extensions can be coupled to the walls of the appliance near edges of the walls, such as a gingivally facing edges of the walls that are oriented toward the gingiva when the appliance is worn.

Abstract: Dental attachment placement apparatuses and methods for positioning and/or replacing dental attachments when bonding the dental attachments on a patient's teeth. The apparatuses may include a body configured for placement on the patient's dental arch. The body may include receptacles for receiving tooth registration anchors. Each tooth registration anchor may include a first end that is detachably connected to a corresponding dental attachment, and a second end that is shaped and sized to fit into a corresponding receptacle of the body to secure the tooth registration anchor to the body. The second end may be removable from the corresponding receptacle to detach the tooth registration anchor from the body.

Abstract: Systems for post-processing additively manufactured objects are disclosed herein. In some embodiments, a system includes a rotor configured to support a plurality of additively manufactured objects having excess material thereon, an actuator configured to spin the rotor so as to remove the excess material from the plurality of additively manufactured objects, and an energy source configured to apply energy to the plurality of additively manufactured objects to selectively alter a material property of a portion of each of the plurality of additively manufactured objects.

Abstract: Dental attachment placement templates and dental appliance systems. The dental attachment placement templates may include a body configured to position a dental attachment over an attachment site on a surface of a tooth. The body may include an aperture, supports that extend from the body within the aperture, a connection member that connects the dental attachment to the supports, and a contoured surface shaped to register with one or more teeth. The connection member may be integrally formed with the dental attachment to provide a unitary structure. The connection member may be joined to the dental attachment at a breakable single point of connection and being further joined to the supports such that when the single point of connection is broken, the dental attachment is detached from the supports.

Abstract: Systems and methods for fabricating dental appliances are provided. In some embodiments, a method includes determining an appliance geometry for a dental appliance, where the appliance geometry includes a first region representing a first shell portion having a first set of cavities configured to receive one or more first teeth at a first side of a dental arch of a patient, a second region representing a second shell portion having a second set of cavities configured to receive one or more second teeth at a second side of the dental arch, and a third region representing an integrally formed arch expander configured to exert forces to increase a width of the dental arch. The method can also include generating instructions for fabricating the dental appliance having the appliance geometry via an additive manufacturing process, and using the instructions to instruct a fabrication system to fabricate the dental appliance.

Abstract: Dental attachment positioning apparatuses and methods of use. A dental attachment apparatus may include an orthodontic attachment having a surface shaped to conform to a contour of a buccal surface of a tooth, and one or more registration surfaces that are shaped to conform to one or more occlusal surfaces of the patient's teeth. The one or more registration surfaces may be configured to aid in proper positioning or orientation of the orthodontic attachment. When the attachment positioning apparatus is placed on the patient's dentition, the orthodontic attachment is positioned at a specified location with respect to the buccal surface of the tooth.

Abstract: Aligner attachment placement devices for placing one or more aligner attachments on teeth. The placement devices can include registration anchors, retention supports, an aligner attachment, and an attachment frame that at least partially surrounds a perimeter of the aligner attachment. The registration anchors can have occlusal contact surfaces that are shaped to register with occlusal surfaces of one or more teeth. The retention supports can have lingual contact surfaces that are shaped to register with lingual surfaces of one or more teeth. The aligner attachments can be shaped to interact with one or more aligners to impart forces on one or more of the teeth. The placement device can include multiple aligner attachments. The attachment frame can include one or more struts that frangibly connect the aligner attachment(s) to the attachment frame.

Abstract: Dental attachment placement apparatuses with one or more replacement attachment systems for providing one or more replacement dental attachments. The replacement attachment systems may include a body that is configured to orient and align the apparatus with respect to the teeth. The apparatus may include one or more primary dental attachments coupled to the body, where the body is configured to position the primary dental attachments adjacent to the teeth for bonding. The replacement system can be configured to replace the primary dental attachments and align replacement dental attachments with respect to the teeth.

Abstract: Methods and systems are provided for generating a treatment plan for arch expansion where a polymeric shell appliance is utilized to generate one or more activation forces that facilitate tooth movement. The polymeric shell appliances may comprise one or more tooth receiving cavities, in which each of the plurality of tooth receiving cavities is shaped and arranged to provide a counter moment of each of the plurality of teeth.

Abstract: Systems, methods, and devices for improved orthodontic treatment of a patient's teeth are provided herein. In some embodiments, a method includes determining an appliance geometry for a dental appliance. The appliance geometry can include a first region representing a shell comprising a plurality of teeth receiving cavities, and a second region representing at least one integrally formed component to be integrally joined to the shell. The method can also include generating instructions including a first digital representation of the shell based on the first region, and a second digital representation of the at least one integrally formed component based on the second region. The method can further include transmitting the instructions to a fabrication system configured to additively manufacture the dental appliance by fabricating the shell based on the first digital representation, concurrently with fabricating the at least one integrally formed component based on the second digital representation.

Abstract: Systems, methods, and devices for post-processing additively manufactured objects are disclosed herein. In some embodiments, a method includes receiving a plurality of additively manufactured objects on a rotor, the plurality of additively manufactured objects having excess material thereon. The method can include removing the excess material from the plurality of additively manufactured objects by rotating the plurality of additively manufactured objects via the rotor. The method can further include applying energy to the plurality of additively manufactured objects to cure a portion of each additively manufactured object while the plurality of additively manufactured objects are on the rotor.