Method for producing tooth replacements and auxiliary dental parts

Abstract

In a method for forming a dental part, a laser beam is guided over a powder layer of biocompatible material. The laser is guided by a computer controlled laser scanning system based on data representing the shape of the cross-section through the shaped body. The powder is substantially melted by the laser beam to form a layer in the shaped body, to build the shaped body entirely from layers of laser-melted material.

1 . A method of making a shaped body for use as a dental part, comprising: 
 guiding a laser beam over a powder layer using a computer-controlled laser scanning system based on data representing the shape of a cross-section through the shaped body, the powder comprising a biocompatible material of grain size in the range from 0 μm to 50 μm, to create a layer in the shaped body;    substantially melting the powder with the laser beam; and    repeating the guiding and melting over successive powder layers using successive cross-sectional representative data so as to build the shaped body entirely from layers of laser-melted material.    
     
     
         2 . The method as recited in  claim 1 , wherein the molten powder substantially maintains the shape of each cross-section through the shaped body.  
     
     
         3  The method as recited in  claim 1 , wherein the shaped body has an average density of up to 98% of the density of the biocompatible material.  
     
     
         4 . The method as recited in  claim 1 , wherein the shaped body has an average density of up to 99.9% of the density of the biocompatible material.  
     
     
         5 . The method as recited in  claim 1 , wherein the powder comprises an alloy with essentially equal proportions of alloy components in each grain of the powder.  
     
     
         6 . The method as recited in  claim 1 , wherein the biocompatible material is a metal alloy.  
     
     
         7 . The method as recited in  claim 1 , wherein the biocompatible material is Ni61.4, Cr22.9, Mo8.8, Nb3.9, Fe2.5, Mn0.4, and Ti0.1.  
     
     
         8 . An intermediate for being made into a shaped dental part for use in a patient's mouth, comprising: 
 a partial body comprising biocompatible material and having a surface shaped to fit in the patient's mouth; and    a layer of powder alloy disposed upon a surface of the partial body and comprising particles of the biocompatible material, the particles generally being of a predetermined density, having varying grain sizes in a range of about 0 μm to about 50 μm, and having essentially equal proportions of alloy components in each particle;    wherein the biocompatible material of the partial body has a density of not less than about 98% of the predetermined density of the particles.    
     
     
         9  The intermediate as recited in  claim 8 , wherein the biocompatible material of the partial body has a density between 98% and 99.9% of the predetermined density.  
     
     
         10  The intermediate as recited in  claim 8 , wherein the biocompatible material is a metal alloy.  
     
     
         11 . The intermediate as recited in  claim 8 , wherein the biocompatible material is 61.4% Ni, 22.9% Cr, 8.8% Mo, 3.9% Nb, 2.5% Fe, 0.4% Mn, and 0.1% Ti.  
     
     
         12 . The intermediate as recited in  claim 8  wherein the particle layer is of a thickness for forming a layer of cohesively maintained biocompatible material, when melted by a guided laser beam, to enlarge the partial body.  
     
     
         13 . An intermediate for being made into a shaped dental part for use in a patient's mouth, comprising: 
 a partial body comprising biocompatible material and having a surface shaped to fit in the patient's mouth; and    a layer of powder alloy disposed upon a surface of the partial body and consisting of particles of biocompatible material generally having a predetermined density and essentially equal proportions of alloy components, the particles further having varying grain sizes in a range of from about 0 μm to about 50 μm;    wherein the biocompatible material of the partial body has a density of not less than about 98% of the predetermined density of the particles; and    wherein the particle layer is of a thickness for forming a layer of cohesively maintained biocompatible material, when melted by a guided laser beam, to enlarge the partial body.    
     
     
         14 . The intermediate as recited in  claim 14 , wherein the biocompatible material is a metal alloy.  
     
     
         15 . The intermediate as recited in  claim 14 , wherein the biocompatible material is 61.4% Ni, 22.9% Cr, 8.8% Mo, 3.9% Nb, 2.5% Fe, 0.4% Mn, and 0.1% Ti.