Align Technology, Inc.

James Clete Culp

Craig E Farren

Stanley E Sankaran

Yevgeniy Sirovskiy

Srinivas Kaza

Shiva Prasad Sambu

Kwan Ho

Samuel J Kass

Sergey Nikolsky

Maneesh Dhagat

Qinghui Lu

Dmitry Sultanov

Pavel Agapov

Steven Shifman

Roman Wrosz

Artem Borovinsklh

Eric E Kuo

Artem Borovinskih

Laser cutting systems and methods are described herein. Systems may include a laser, an optical component, a fixture for holding a dental appliance, and a controller. A cut path for trimming excess material from the dental appliance may be derived from a virtual cut path in a virtual version of the dental appliance. The excess material may be trimmed from the dental appliance along the cut path with the laser while adjusting a laser energy applied to the dental appliance to reduce a brittleness at an edge of the cut path. Adjusting the applied laser energy may include adjusting one or more of: a power of the laser, an optical component of the laser to adjust a focal length of the laser, and a relative orientation of the laser with respect to the dental appliance in at least three axes of movement.

Laser cutting

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.

Methods for manufacturing thermoformed objects

Methods for controlling the sorting and sequencing of objects are provided. In some embodiments, a method includes receiving sensor data of a plurality of dental appliances, each dental appliance associated with an identifier including (a) group data indicating a group to which the dental appliance belongs, and (b) sequence data indicating a sequential position for the dental appliance within the group. The method can include controlling a sorting cell to direct each dental appliance into one of a plurality of buffer locations based on the group data for the dental appliance, where each buffer location is configured to hold a set of dental appliances belonging to the same group; and controlling a sequencing cell to sequence the set of dental appliances associated with each buffer location by placing each dental appliance into a position within the corresponding set of dental appliances based on the sequence data for the dental appliance.

Methods for controlling object sorting and sequencing

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.

Systems for thermal forming an object

Laser cutting systems and methods are described herein. One or more systems include a laser, an optical component, a fixture for holding a support with a part positioned on the support, and a controller. The controller is configured to identify a cut path for trimming excess material from a dental appliance, determine adjustment instructions for adjusting a focal length of the laser to cut along the cut path, and trim the excess material from the dental appliance along the cut path with the laser. The focal length is adjusted by adjusting at least one of: the laser, the optical component, and the fixture, and while moving the fixture at a constant speed relative to the laser to avoid increasing a brittleness of a polymer material of the dental appliance along the cut path.

Methods for sorting and sequencing objects are provided. In some embodiments, a method includes receiving a plurality of objects, each object associated with an identifier including group data identifying a group to which the object belongs, and sequence data identifying a sequential position for the object within the group. The method can include determining the group data and the sequence data for each object by reading the identifier associated with the object; sorting the plurality of objects by directing each object into one of a plurality of buffer locations based on the group data for the object; and sequencing the set of objects associated with each buffer location by placing each object into a position within the corresponding set of objects based on the sequence data for the object.

Methods for sorting and sequencing objects

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.

Methods and systems for thermal forming an object

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.

Methods for thermal forming an object

Laser cutting systems and methods are described herein. One or more systems include a laser generating component, an optical component, a fixture for holding a support with a part positioned on the support, and a control mechanism for adjusting at least one of the laser generating component, the optical component, and the fixture such that a ratio of a laser energy applied to the part and a part material thickness is maintained within a predetermined acceptable range at each point along a cut path to cut through the part while maintaining the integrity of the support. Other systems and methods are disclosed herein.

A system and associated method is provided for sorting parts, which includes a conveyor system for receiving and circulating a plurality of randomly presented parts, a sorting buffer for accumulating selected parts from the plurality of randomly presented parts in an assigned buffer location, and a sequencing system for sequencing the accumulated selected parts.

Growing community of inventors

Pleasanton, CA, United States of America

James Clete Culp