Align Technology, Inc.

Mehdi Mojdeh

Michael Christopher Cole

Shiva Prasad Sambu

John Y Morton

Jun Sato

Sriram Venkatasanthanam

Ramin Heydarpour

Jeremy Riley

Peter Dorfinger

Prashanth Vanchy

Natalia Lysaya Powers

Sibel Narin

Alexey Kalinichenko

Jack Shaw

Brett E Kelly

Enrique Soltero Borrego

Gabor Lukacs

Arthur George Butz

Dennis McNamara

A system includes a mold of a dental arch of a patient. The mold includes teeth extending from a first distal end of the dental arch to a second distal end of the dental arch. An orthodontic aligner is to be formed over the teeth of the mold. The teeth of the mold are shaped to correspond to tooth-receiving cavities of the orthodontic aligner. The system includes a pre-fabricated attachment that includes a traceability component configured to be used to determine one or more identifiers corresponding to the mold. The pre-fabricated attachment further includes a handling component configured to be secured by a robot or person to transport the mold and the pre-fabricated attachment during production of the orthodontic aligner.

Attachments for fabricated custom objects

A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape.

Hybrid 3d printing techniques

A three-dimensional (3D) object comprises a plurality of layers representative of an additive manufacturing process, wherein each layer of the plurality of layers approximately has a first thickness. A first layer of the plurality of layers forms at least a portion of a first surface of the 3D object, the first layer comprising a support region and an overcure region, wherein the first layer approximately has the first thickness at the support region and a greater second thickness at the overcure region. A support mark is included at the support region, wherein the support mark is inset from a first surface profile of the 3D object defined by the overcure region.

3D printed object having overcure region

A method for forming dental appliance having an ornamental indicia carrier may include forming a polymeric shell, forming a first adhesive layer configured to be adhered to the polymeric shell, the first adhesive layer including a pressure sensitive adhesive layer, forming a first adhesion layer over the first adhesive layer, and applying a colorant between the first adhesion layer and the pressure sensitive adhesive layer.

Indicia for dental appliances

A method of 3D printing comprises extruding one or more photo-curable materials from a nozzle to form a first layer that has a first shape specified by the one or more digital files, wherein the first shape corresponds to a first minimum line width that is based on, and narrower than, a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the one or more digital files to cure a portion of the first layer to create a first cured layer, wherein the first cured layer corresponds to a second shape of a first layer of a 3D printed orthodontic aligner, wherein the light beam has a beam diameter that is smaller than the diameter of the nozzle, and wherein the second shape has a second minimum line width that is smaller than the first minimum line width.

Hybrid 3D printing with photo-curable materials

Embodiments relate to a pre-fabricated attachment for fabricating custom objects. In one embodiment, a system includes a mold and a pre-fabricated attachment. The mold includes a physical model of a dental arch of a patient and one or more first features. An orthodontic aligner is to be formed over the physical model. The pre-fabricated attachment includes one or more second features configured to removably attach to the one or more first features. The pre-fabricated attachment further includes a traceability component configured to be used to determine one or more identifiers corresponding to the mold. The pre-fabricated attachment further includes a handling component configured to be secured by a robot or person to transport the mold and pre-fabricated attachment during production of the orthodontic aligner. The pre-fabricated attachment may be reused.

Attachments for handling and tracking fabricated custom objects

The present disclosure relates to ornamental indicia carrier and method of producing the same. In some embodiments, the ornamental indicia carrier comprises an ultraviolet light ('UV') cured ink printed on a thin flexible film and combined with an adhesive layer. The ornamental indicia carrier is capable of enduring the conditions inside the mouth for an extended period of time and can be used in conjunction with a dental appliance.

Durable ornamental indicia carrier

A 3D printer comprises a platform, a dispenser and a light source. A heating element heats a material and a nozzle extrudes the heated material onto the platform to form a first layer, having a first shape specified by one or more digital files. The first shape corresponds to a first minimum line width based on a diameter of the nozzle. The light source emits a light beam that is directed onto the first layer according to the one or more digital files to cure a portion of the first layer to create a first cured layer that corresponds to a second shape of a 3D object specified by the one or more digital files. The light beam has a beam diameter that is smaller than the diameter of the nozzle, and the second shape has a second minimum line width that is smaller than the first minimum line width.

System for hybrid 3D printing with photo-curable materials

A method of manufacturing a three-dimensional (3D) object may include fabricating a support structure and fabricating the 3D object on the support structure, wherein the support structure contacts the 3D object at a support region of the 3D object. The method further includes overcuring the 3D object at an overcure region of the 3D object, wherein the overcure region is distinct from the support region, and removing the support structure from the 3D object. After removal of the support structure, a support mark remains on the 3D printed object where the support structure had contacted the 3D object, wherein the overcure region of the 3D object projects past the support mark.

3D printed objects with selective overcure regions

Embodiments relate to automating removal of an untrimmed shell from a mold. In one embodiment, a shell removal device includes a body and a platform disposed within the body. The platform is configured to secure a mold that has an untrimmed shell formed over the mold. The shell removal device further includes a cover configured to secure the untrimmed shell to an upper surface of one or more sidewalls of the body and provide a seal between a lower surface of the untrimmed shell and the upper surface of the one or more sidewalls of the body. The shell removal device may include a media inlet in the body to permit pressurized media into the interior of the body to cause a pressure differential between an upper surface of the untrimmed shell and the lower surface of the untrimmed shell to cause the untrimmed shell to release from the mold.

Growing community of inventors

Fremont, CA, United States of America

Mehdi Mojdeh