Addressable matrices/cluster blanks for dental cad/cam systems and optimization thereof

Abstract

A cluster mill blank includes a framework constructed to cooperate with a blank holder of an existing CAD/CAM system, and a plurality of sub-blanks attached to the framework forming an addressable matrix or cluster blank. CAD/CAM systems including such a framework, as well as associated methods are described.

1 . A system for milling dental prostheses in a CNC milling machine, comprising:
 a) a primary fixture of a milling machine for receiving a large millable dental blank;   b) a plurality of smaller millable dental blanks each capable of being machined to form a dental prosthesis; and   c) lateral affixing means for affixing a lateral side of the plurality of smaller millable dental blanks in a space defined by the large millable dental blank in the primary fixture.   
   
   
       2 . The system of  claim 1 , wherein the millable dental blanks comprise ceramic, metal or plastic blanks. 
   
   
       3 . The system of  claim 1 , wherein the lateral affixing means comprises an interchangeable jig sized and shaped as the large millable dental blank and interchangeable with the large millable dental blank in a receptacle of the primary fixture, and having a lateral wall against which the lateral side of the plurality of smaller millable dental blanks is affixed. 
   
   
       4 . The system of  claim 3 , wherein the jig comprises a plastic tray having a plurality of alignment indentations for receiving the plurality of smaller millable dental blanks. 
   
   
       5 . The system of  claim 4 , wherein the plastic tray is made from the large millable blank using the same CNC milling machine. 
   
   
       6 . The system of  claim 5  wherein the large millable blank is a PMMA disk. 
   
   
       7 . A system for milling dental prostheses in a CNC milling machine, comprising:
 a) primary fixture of a milling machine for receiving a large millable blank;   b) an interchangeable jig sized and shaped as the large millable dental blank and interchangeable with the large millable dental blank with respect to the primary fixture of the milling machine, and having a lateral wall; and   c) a plurality of smaller millable dental blanks each with a lateral side affixed to the lateral wall of the jig.   
   
   
       8 . The system of  claim 7 , wherein the interchangeable jig comprises a variety of jigs interchangeable with the primary fixture or fixtures to mill a variety of commercially available plastic, metal and ceramic dental blanks. 
   
   
       9 . The system of  claim 8 , wherein the jig comprises a plastic tray having a plurality of alignment indentations for receiving the plurality of smaller millable dental blanks. 
   
   
       10 . The system of  claim 9 , wherein the plastic tray is made from the large millable blank using the same CNC milling machine. 
   
   
       11 . The system of  claim 10 , wherein the large millable blank is a PMMA disk. 
   
   
       12 . A method for milling dental prostheses in a CNC milling machine, comprising:
 providing a primary fixture for receiving a large millable blank;   affixing a lateral side of one or more smaller millable dental blanks in the same space provided for the large millable dental blank;   milling one or more dental prostheses in the smaller millable dental blanks; and   removing the one or more dental prostheses from the smaller millable dental blanks.   
   
   
       13 . A method for milling dental prosthesis in a CNC milling machine, comprising:
 providing a primary fixture for receiving a large millable blank;   affixing a lateral side of one or more smaller millable dental blanks to a lateral wall of a jig sized and shaped as the large millable dental blank;   placing the jig in the primary fixture held in the milling machine;   milling one or more dental prostheses in the smaller millable dental blanks;   removing the jig from the primary fixture; and   removing the smaller millable dental blanks from the jig.   
   
   
       14 . The method of  claim 13 , wherein the jig comprises a variety of jigs interchangeable with the primary fixture or fixtures to mill a variety of commercially available plastic, metal and ceramic blanks. 
   
   
       15 . A method for machining dental prostheses in a CNC milling machine, wherein the milling machine comprises at least one type of a blank holding fixture cooperating with a chuck of the milling machine, the method comprising:
 affixing a lateral side of each of a plurality of ceramic millable dental blanks to a lateral wall of the fixture;   securing the fixture to the chuck of the milling machine;   machining a single dental prosthesis in each of the plurality of ceramic millable dental blanks by a machining process with machining tools; and   removing the plurality of ceramic millable dental blanks from the fixture.   
   
   
       16 . The method of  claim 15 , wherein the machining tools comprise diamond burrs or fluted cutters. 
   
   
       17 . The method of  claim 15 , wherein the machining process comprises wet or dry machining. 
   
   
       18 . A method for milling dental prostheses in a CNC milling machine, comprising:
 affixing a lateral side of each of a plurality of ceramic millable dental blanks to internal lateral walls of an internal periphery and/or internal holders of a fixture by disposing a post of each of the plurality of ceramic millable dental blanks in a different one of a plurality of holes in the fixture, with the plurality of ceramic millable dental blanks disposed in a flat layer with a top and a bottom of each of the plurality of ceramic millable dental blanks unblocked by another of the plurality of ceramic millable dental blanks, each of the plurality of ceramic millable dental blanks having a different characteristic with respect to one another;   securing the fixture to a chuck of the milling machine;   milling a single dental prosthesis in each of the plurality of ceramic millable dental blanks with a diamond burr by first milling a top side of each of the plurality of ceramic millable dental blanks, turning the fixture over, and then milling an opposite bottom side of each of the plurality of ceramic millable dental blanks; and   removing the plurality of ceramic millable dental blanks from the fixture.   
   
   
       19 . A system for milling dental prostheses, comprising:
 a) a CNC milling machine capable of a wet-milling process with a chuck, a diamond bun, and a liquid delivery system;   b) a fixture securable in the chuck of the milling machine;   c) a plurality of ceramic millable dental blanks each capable of being machined to form a dental prosthesis; and   d) a lateral side of each of the plurality of ceramic millable dental blanks securable to a lateral wall(s) of the fixture.   
   
   
       20 . A method of making a jig for a CNC milling machine for milling dental prostheses comprising:
 inserting a large blank into a fixture of the CNC milling machine;   milling openings in the large blank, wherein the openings are used to receive smaller millable dental blanks.   
   
   
       21 . The method of  claim 20 , wherein the large blank is disk-shaped. 
   
   
       22 . The method of  claim 20 , wherein the large blank is fabricated of plastic, metal or ceramic. 
   
   
       23 . The method of  claim 22 , wherein the plastic comprises PMMA. 
   
   
       24 . The method of  claim 20 , wherein the openings milled in the large blank are modified by addition of adapters, gaskets, liners or castable materials to assure tight secure fit of the smaller millable dental blanks. 
   
   
       25 . A method of milling dental prostheses in a CNC milling machine, comprising:
 inserting a large blank into a fixture of the CNC milling machine;   milling openings in the large blank, wherein the openings are used to receive smaller millable dental blanks;   inserting smaller millable dental blanks into the openings in the large blank; and   milling the dental blanks into dental prostheses.   
   
   
       26 . The method of  claim 25 , wherein the large blank is disk-shaped. 
   
   
       27 . The method of  claim 25 , wherein the openings milled in the large blank are modified by addition of adapters, gaskets, liners or castable materials to assure tight secure fit of the smaller millable dental blanks.