System and method for mass custom manufacturing of dental crowns and crown components

Abstract

A Mass Custom Manufacturing System and methods are provided. A single master file is created for a restoration (or multiple restorations for a single patient) from a scan. Copings/cores, abutments and other companion pieces are designed using the master file through a deconstruction method allowing for simultaneous CAM of those pieces. A centralized system controls design and manufacturing, allowing the system to “learn” from feedback from the CAM operations of prior pieces and incorporate such feedback into the design phase.

What is claimed is: 
     
         1 . A method of Mass Custom Manufacturing of dental crowns and crown components comprising the steps of:
 obtaining digital file information of a dental condition representative of the condition of a patient's mouth;   creating automatically a master electronic file based upon the information, the master electronic file including a virtual model and a virtual final external shape of an ideal tooth of a restoration within the virtual model for the patient;   deconstructing from the master file to design two or more components of the restoration.   
     
     
         2 . The method as claimed in  claim 1  further comprising the step of manufacturing said two or more components based upon data from said master file. 
     
     
         3 . The method as claimed in  claim 2  wherein the components are made from an end state material or through a controllable process that results in the material assuming end state properties. 
     
     
         4 . The method as claimed in  claim 2  wherein said step of manufacturing comprises the step of controlling multiple manufacturing machines simultaneously, multiple machines sequentially, or a single machine sequentially, by a central control system. 
     
     
         5 . The method as claimed in  claim 4  further comprising the step of learning adaptively from said prior creating, deconstruction and/or manufacturing steps. 
     
     
         6 . The method as claimed in  claim 4  wherein said central control system is capable of simultaneously manufacturing said two or more components on two or more different machines. 
     
     
         7 . The method as claimed in  claim 4  wherein said central control system controls machines for manufacturing any of implant abutments, temporary crowns, cores/copings, crown molds and crowns. 
     
     
         8 . The method as claimed in  claim 1  wherein said deconstructing step comprises the step of:
 subtracting a thickness of an outer component from the final external shape of the restoration to determine a shape and orientation of an inner component. 
 
     
     
         9 . A system for Mass Custom Manufacturing of crowns and crown components comprising:
 a data input device for obtaining digital file information of dental condition representative of the real condition of a patient's mouth; and   a master file based upon data from said data input device, said master file containing data regarding at least two components of the restoration.   
     
     
         10 . The system as claimed in  claim 9  further comprising:
 a central controller; and 
 at least one manufacturing machine controlled by said central controller. 
 
     
     
         11 . The system as claimed in  claim 10  wherein said at least one machine comprises multiple machines controlled simultaneously to manufacture said at least two components. 
     
     
         12 . The system as claimed in  claim 10  wherein said at least one machine comprises a single machine controlled sequentially to manufacture said at least two components. 
     
     
         13 . The system as claimed in  claim 10  wherein said central controller controls a CAD system for creating said master file. 
     
     
         14 . The system as claimed in  claim 10  wherein said central controller controls a robot capable of unloading finished pieces from said machines. 
     
     
         15 . The system as claimed in  claim 14  where said robot is further capable of loading and unloading raw materials, packages/boxes with models, and models. 
     
     
         16 . The system as claimed in  claim 10  wherein said central controller provides updates to a design file in a CAD system that creates said master file. 
     
     
         17 . The system as claimed in  claim 9  wherein said data input device comprises a scanner. 
     
     
         18 . The system as claimed in  claim 18  wherein said scanner is utilized to scan a model or impression of the patients mouth, said model or impression being representative of the condition of the patient's mouth.