Abstract: Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.

Abstract: An orthodontic appliance made by a thermal forming process is provided. The thermal forming process can include heating a thermoformable material using a plurality of independently controllable heat sources. The plurality of independently controllable heat sources can produce at least one overlapping heating zone. The thermal forming process can further include monitoring one or more temperatures from a plurality of temperature sensing elements operably coupled to different areas of the thermoformable material. The thermal forming process can further include adjusting power of one or more of the plurality of independently controllable heat sources based on the one or more monitored temperatures such that each of the different areas of the thermoformable material reaches a respective desired temperature. The thermal forming process can further include disposing the heated thermoformable material over at least a portion of a mold to form the orthodontic appliance.

Abstract: A computer-implemented method for marking an object on an aligner. The aligner surface is modeled. The method includes calculating a normal for each tile in a tessellated surface and disqualifying a tile from being selected. For tiles not disqualified, a patch is identified that produces a markable area. The method includes selecting an object to be marked, calculating a location of the object in the markable area, and providing the location of the object to a marking device. Disqualifying includes comparing an angle between a normal and an orientation of the beam to an origin of the calculated normal on each tile. Disqualifying includes disqualifying the at least one tile when the angle is outside of a range of ?90° to +90°. Identifying the patch includes separating the patch into at least two smaller patches, and one of the two smaller patches of tiles is the markable area.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including a three-dimensional model of one or more intraoral surfaces of the patient. The trimline is for use to manufacture an aligner. For one or more pairs of adjacent teeth, a scallop plane is defined based on a scallop factor. The scallop plane is used to determine the position of scallop points on a line around each tooth adjacent to an interproximal region of the pair of teeth. Transition points are then defined on the line around each tooth apically of the scallop points, and the points connected to form an initial connector curve. The initial connector curve is projected on to a mesh of the three-dimensional model, and smoothing applied to the resulting segmented connector curve. The smoothed connector curves are then joined by teeth curves to form the trimline.

Abstract: Methods for manufacturing thermoformed objects are provided. In some embodiments, a method includes controlling a material transport system to move a material to a first location proximate to one or more heat sources. The method can include controlling the one or more heat sources to heat a first region of the material to a first temperature and heat a second region of the material to a second temperature. The method can also include controlling the material transport system to move the material to a second location proximate to an object forming element, and controlling the object forming element to form a dental appliance from the material.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including a three-dimensional model of one or more intraoral surfaces of the patient. The trimline is for use to manufacture an aligner. For one or more pairs of adjacent teeth, a scallop plane is defined based on a scallop factor. The scallop plane is used to determine the position of scallop points on a line around each tooth adjacent to an interproximal region of the pair of teeth. Transition points are then defined on the line around each tooth apically of the scallop points, and the points connected to form an initial connector curve. The initial connector curve is projected on to a mesh of the three-dimensional model, and smoothing applied to the resulting segmented connector curve. The smoothed connector curves are then joined by teeth curves to form the trimline.

Abstract: Systems for thermal forming an object are provided. In some embodiments, a system for thermal forming an object using a mold includes one or more processors, and memory including instructions that, when executed by the one or more processors, cause the system to perform the following operations: receiving a mold identifier identifying the mold; determining mold process information for forming the object based on the mold identifier; inserting a material into a heating area, the material having a geometry selected based on the mold process information; heating the material using one or more independently controllable heat sources; and forming the object by disposing the heated material over or into at least a portion of the mold.

Abstract: Methods for manufacturing thermoformed objects are provided. In some embodiments, a method includes controlling a material transport system to move a material to a first location proximate to one or more heat sources. The method can include controlling the one or more heat sources to heat a first region of the material to a first temperature and heat a second region of the material to a second temperature. The method can also include controlling the material transport system to move the material to a second location proximate to an object forming element, and controlling the object forming element to form a dental appliance from the material.

Abstract: A method and system for thermal forming an object. A mold is provided, a shape of which corresponds to a desired shape of the object. A material is inserted into a heating area, and the material is heated using a plurality of independently controllable heat sources that heat different areas of the material. The heated material is then disposed over or into at least a portion of the mold so as to deform the material. The deformed material may then be trimmed so as to form the object.

Abstract: Systems for thermal forming an object are provided. In some embodiments, a system for thermal forming an object using a mold includes one or more processors, and memory including instructions that, when executed by the one or more processors, cause the system to perform the following operations: receiving a mold identifier identifying the mold; determining mold process information for forming the object based on the mold identifier; inserting a material into a heating area, the material having a geometry selected based on the mold process information; heating the material using one or more independently controllable heat sources; and forming the object by disposing the heated material over or into at least a portion of the mold.

Abstract: Methods for thermal forming an object are provided. In some embodiments, a method includes reading a mold identifier located on or in a mold, and determining mold process information from the mold identifier, the mold process information including heating information. The method can include heating a thermoformable material according to the heating information by adjusting power of one or more independently controllable heat sources. The method can also include monitoring one or more temperatures from a plurality of temperature sensing elements operably coupled to different areas of the thermoformable material. The thermoformable material can be heated according to the heating information and in response to the one or more monitored temperatures such that each of the different areas of the thermoformable material reach a respective desired temperature. The method can further include disposing the heated thermoformable material over at least a portion of the mold to form the object.

Abstract: A computer-implemented method for marking an object on an aligner. The aligner surface is modeled. The method includes calculating a normal for each tile in a tessellated surface and disqualifying a tile from being selected. For tiles not disqualified, a patch is identified that produces a markable area. The method includes selecting an object to be marked, calculating a location of the object in the markable area, and providing the location of the object to a marking device. Disqualifying includes comparing an angle between a normal and an orientation of the beam to an origin of the calculated normal on each tile. Disqualifying includes disqualifying the at least one tile when the angle is outside of a range of ?90° to +90°. Identifying the patch includes separating the patch into at least two smaller patches, and one of the two smaller patches of tiles is the markable area.

Abstract: A method and system for thermal forming an object. A mold is provided, a shape of which corresponds to a desired shape of the object. A material is inserted into a heating area, and the material is heated using a plurality of independently controllable heat sources that heat different areas of the material. The heated material is then disposed over or into at least a portion of the mold so as to deform the material. The deformed material may then be trimmed so as to form the object.

Abstract: A computer-implemented method for marking an object on an aligner. The aligner surface is modeled. The method includes calculating a normal for each tile in a tessellated surface and disqualifying a tile from being selected. For tiles not disqualified, a patch is identified that produces a markable area. The method includes selecting an object to be marked, calculating a location of the object in the markable area, and providing the location of the object to a marking device. Disqualifying includes comparing an angle between a normal and an orientation of the beam to an origin of the calculated normal on each tile. Disqualifying includes disqualifying the at least one tile when the angle is outside of a range of ?90° to +90°. Identifying the patch includes separating the patch into at least two smaller patches, and one of the two smaller patches of tiles is the markable area.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including a three-dimensional model of one or more intraoral surfaces of the patient. The trimline is for use to manufacture an aligner. For one or more pairs of adjacent teeth, a scallop plane is defined based on a scallop factor. The scallop plane is used to determine the position of scallop points on a line around each tooth adjacent to an interproximal region of the pair of teeth. Transition points are then defined on the line around each tooth apically of the scallop points, and the points connected to form an initial connector curve. The initial connector curve is projected on to a mesh of the three-dimensional model, and smoothing applied to the resulting segmented connector curve. The smoothed connector curves are then joined by teeth curves to form the trimline.

Abstract: Systems and methods of defining a trimline in relation to modeled teeth including modeled gingiva. The trimline is for use to manufacture an aligner. A margin point is placed proximate a gingival margin at each tooth on at least one jaw in the model. A trimline connects the plurality of margin points from which machine code is generated. The aligner manufactured includes an edge that correlates with the trimline according to the machine code. A margin point may be proximate a gingival zenith. At least one tooth cooperates with the modeled gingiva to define a line around the tooth. The trimline includes at least one tooth curve and at least one connector curve connected to the tooth curve at a transition point. At least one control point is on the trimline between two margin points. The trimline is defined by a spline that may be a Bèzier curve.

Abstract: A method and system for thermal forming an object. A mold is provided, a shape of which corresponds to a desired shape of the object. A material is inserted into a heating area, and the material is heated using a plurality of independently controllable heat sources that heat different areas of the material. The heated material is then disposed over or into at least a portion of the mold so as to deform the material. The deformed material may then be trimmed so as to form the object.

Abstract: An aligner fabrication system combines design data and material to form a plurality of dental molds with which a plurality of aligners are formed. The aligner fabrication system includes a build assembly that defines a build surface on which the dental molds are formed. The build assembly is constructed of a plurality of individual build platforms that are removably coupled together. Each individual build platform is associated with an identification entity. The dental molds are formed on the build surface. One dental mold is formed on one individual build platform. The design data associated with the one dental mold is linkable to the identification entity on the one individual build platform.