Abstract: A customized orthodontic bracket system is provided. The system can include a bracket having a customized bracket bonding pad for bonding the bracket to a tooth of a patient and a bracket slot adapted to receive a customized archwire. The customized archwire is adapted to be positioned in the bracket slot to form a precise bracket slot-archwire interface. The bracket slot and the archwire when positioned in the bracket slot can be positioned substantially adjacent the tooth surface to reduce induced vertical error in tooth positioning. The bracket slot can be configured to have a bracket slot width substantially matching a cross-section of the archwire to reduce torque rotation around an axis of the archwire when positioned therein to further enhance end-of-treatment tooth positioning and reduce overall treatment time.

Abstract: Occlusal contact between upper and lower virtual three-dimensional teeth of a patient when the upper and lower arches are in an occlused condition are determined and displayed to the user on a user interface of a general purpose computing device. Various techniques for determining occlusal contacts are described. The areas where occlusal contact occurs is displayed on the user interface in a readily perceptible manner, such as by showing the occlusal contacts in green. If the proposed set-up would result in a interpenetration of teeth in opposing arches, such locations of interpenetration are illustrated in a contrasting color or shading (e.g., red). The ability to calculate distances and display occlusal contacts in a proposed set-up assists the user in planning treatment for the patient. The process can be extended to interproximal contact detection as well. The concepts also apply to dental prosthetics, such as crowns, fillings and dentures.

Abstract: A customized orthodontic bracket system is provided. The system can include a bracket having a customized bracket bonding pad for bonding the bracket to a tooth of a patient and a bracket slot adapted to receive a customized archwire. The customized archwire is adapted to be positioned in the bracket slot to form a precise bracket slot-archwire interface. The bracket slot and the archwire when positioned in the bracket slot can be positioned substantially adjacent the tooth surface to reduce induced vertical error in tooth positioning. The bracket slot can be configured to have a bracket slot width substantially matching a cross-section of the archwire to reduce torque rotation around an axis of the archwire when positioned therein to further enhance end-of-treatment tooth positioning and reduce overall treatment time.

Abstract: Interactive, computer based orthodontist treatment planning, appliance design and appliance manufacturing is described. A scanner is described which acquires images of the dentition which are converted to three-dimensional frames of data. The data from the several frames are registered to each other to provide a complete three-dimensional virtual model of the dentition. Individual tooth objects are obtained from the virtual model. A computer-interactive software program provides for treatment planning, diagnosis and appliance from the virtual tooth models. A desired occlusion for the patient is obtained from the treatment planning software. The virtual model of the desired occlusion and the virtual model of the original dentition provide a base of information for custom manufacture of an orthodontic appliance.

Abstract: A customized orthodontic bracket system is provided. The system can include a bracket having a customized bracket bonding pad for bonding the bracket to a tooth of a patient and a bracket slot adapted to receive a customized archwire. The customized archwire is adapted to be positioned in the bracket slot to form a precise bracket slot-archwire interface. The bracket slot and the archwire when positioned in the bracket slot can be positioned substantially adjacent the tooth surface to reduce induced vertical error in tooth positioning. The bracket slot can be configured to have a bracket slot width substantially matching a cross-section of the archwire to reduce torque rotation around an axis of the archwire when positioned therein to further enhance end-of-treatment tooth positioning and reduce overall treatment time.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

Abstract: A customized orthodontic bracket system is provided. The system can include a bracket having a customized bracket bonding pad for bonding the bracket to a tooth of a patient and a bracket slot adapted to receive a customized archwire. The customized archwire is adapted to be positioned in the bracket slot to form a precise bracket slot-archwire interface. The bracket slot and the archwire when positioned in the bracket slot can be positioned substantially adjacent the tooth surface to reduce induced vertical error when the tooth is in a finished position and substantially parallel to the directly adjacent portion of the tooth surface to reduce bracket thickness. The bracket slot can also be configured to have a bracket slot width substantially matching a dimension of a cross-section of the archwire to reduce torque rotation around an axis of the archwire when positioned therein to further enhance end-of-treatment tooth positioning and reduce overall treatment time.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The gripping tools preferably incorporate force sensors which are used to determine overbends needed to get the desired final shape of the archwire. The robot may also include a resistive heating system in which current flows through the wire while the wire is held in a bent condition to heat the wire and thereby retain the bent shape of the wire.

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.

Abstract: A robotic bending apparatus for bending archwires and other types of elongate, bendable medical devices into a desired configuration includes a first gripping tool and a moveable gripping tool. The first gripping tool can be either fixed with respect to a base or table for the robot or positioned at the end of robot am. The moveable gripping tool is mounted to the end of a moveable robot arm having a proximal portion also mounted to the base. The robot preferably comprises a six axis bending robot, in which the distal end of the moveable arm can move relative to the fixed gripping tool about three translational axes and three rotational axes. The robot bending system is able to form archwires with any required second and third order bends quickly and with high precision.

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.

Abstract: A method is described for taking a three-dimensional virtual model of the dentition and associated anatomical structures of a patient and isolating individual teeth from the rest of the anatomical structure, e.g. gums, to thereby produce individual, virtual three-dimensional tooth objects. The individual tooth objects can be displayed on the display of an orthodontic workstation and moved independently from each other, and thereby form the basis of planning treatment for the patient. The individual, virtual three-dimensional tooth objects are created by comparing the virtual model of the dentition to virtual, three-dimensional template teeth that are stored in memory in a process described in detail herein. The template teeth can include roots as well as crowns. The template teeth can be stored objects acquired from some external source or alternatively developed from a database of patient scans. Virtual three-dimensional brackets are also stored in the memory of the workstation.

Abstract: Interactive, computer based orthodontist treatment planning, appliance design and appliance manufacturing is described. A scanner is described which acquires images of the dentition which are converted to three-dimensional frames of data. The data from the several frames are registered to each other to provide a complete three-dimensional virtual model of the dentition. Individual tooth objects are obtained from the virtual model. A computer-interactive software program provides for treatment planning, diagnosis and appliance from the virtual tooth models. A desired occlusion for the patient is obtained from the treatment planning software. The virtual model of the desired occlusion and the virtual model of the original dentition provide a base of information for custom manufacture of an orthodontic appliance.

Abstract: Interactive, computer based orthodontist treatment planning, appliance design and appliance manufacturing is described. A scanner is described which acquires images of the dentition which are converted to three-dimensional frames of data. The data from the several frames are registered to each other to provide a complete three-dimensional virtual model of the dentition. Individual tooth objects are obtained from the virtual model. A computer-interactive software program provides for treatment planning, diagnosis and appliance from the virtual tooth models. A desired occlusion for the patient is obtained from the treatment planning software. The virtual model of the desired occlusion and the virtual model of the original dentition provide a base of information for custom manufacture of an orthodontic appliance.

Abstract: An interactive, software-based treatment planning method to correct a malocclusion is described. The method can be performed on an orthodontic workstation in a clinic or at a remote location such as a lab or precision appliance manufacturing center. The workstation stores a virtual three-dimensional model of the dentition of a patient and patient records. The virtual model is manipulated by the user to define a target situation for the patient, including a target archform and individual tooth positions in the archform. Parameters for an orthodontic appliance, such as the location of orthodontic brackets and resulting shape of an orthodontic archwire, are obtained from the simulation of tooth movement to the target situation and the placement position of virtual brackets. The treatment planning can also be executed remotely by a precision appliance service center having access to the virtual model of the dentition.

Abstract: Method and apparatus for registering an object of known predetermined geometry to scanned three dimensional data such that the object's location may be verified. Such a known object may comprise a less than ideal three-dimensional (3-D) digital object such as a tooth, a dental appliance (e.g., as a tooth bracket model) or other like object, including portions thereof. Knowledge of such an object's location is generally helpful in planning orthodontic treatment, particularly where the location of the object needs to be determined or confirmed or where incomplete or poor scan data is obtained. Aspects of the present invention provide methods of effectively verifying dental appliance location and displaying appliance locations using a computer and three-dimensional models of teeth.

Abstract: Occlusal contact between upper and lower virtual three-dimensional teeth of a patient when the upper and lower arches are in an occlused condition are determined and displayed to the user on a user interface of a general purpose computing device. Various techniques for determining occlusal contacts are described. The areas where occlusal contact occurs is displayed on the user interface in a readily perceptible manner, such as by showing the occlusal contacts in green. If the proposed set-up would result in a interpenetration of teeth in opposing arches, such locations of interpenetration are illustrated in a contrasting color or shading (e.g., red). The ability to calculate distances and display occlusal contacts in a proposed set-up assists the user in planning treatment for the patient. The process can be extended to interproximal contact detection as well. The concepts also apply to dental prosthetics, such as crowns, fillings and dentures.

Abstract: A method for monitoring tooth wear and a method for monitoring tooth wear and gingival recession and erosion by comparing three-dimensional virtual models at different times are described, as well as occlusal contact between upper and lower virtual three-dimensional teeth of a patient when the upper and lower arches are in an occluded condition are determined and displayed to the user on a user interface of a general purpose computing device. Various techniques for determining occlusal contacts are described. The areas where occlusal contact occurs is displayed on the user interface in a readily perceptible manner, such as by showing the occlusal contacts in green. If the proposed set-up would result in a interpenetration of teeth in opposing arches, such locations of interpenetration are illustrated in a contrasting color or shading (e.g., red). The ability to calculate distances and display occlusal contacts in a proposed set-up assists the user in planning treatment for the patient.

Abstract: A method and system are provided for constructing a virtual three-dimensional model of an object using a data processing system, and at least one machine-readable memory accessible to said data processing system. A set of at least two digital three-dimensional frames of portions of the object are obtained from a source, such as a computing system coupled to an optical or laser scanner, CT scanner, Magnetic Resonance Tomography scanner or other source. The at least two frames comprise a set of point coordinates in a three dimensional coordinate system providing differing information of the surface of the object. The frames provide a substantial overlap of the represented portions of the surface of the object, but do not coincide exactly for example due to movement of the scanning device relative to the object between the generation of the frame. Data representing the set of frames are stored in the memory.

Abstract: An orthodontic workstation stores a library of virtual three-dimensional brackets in a memory. Each of the virtual brackets has a unique three-dimensional configuration and prescription. Typically, the library of bracket comprises a library of commercially available, off-the-shelf brackets. The workstation further includes an interactive treatment planning program that permits a user to move teeth from a virtual model of the dentition to a proposed set-up. In one possible embodiment, the treatment planning program provides the ability to display a virtual bracket placed on a virtual tooth and change the prescription or configuration of the virtual bracket. The treatment program automatically compares the modified prescription with the prescription information of the virtual brackets in the library and selects a bracket from the library that most closely matches the virtual bracket displayed on the tooth. Thus, the user does not have to use customized brackets.