System and method for 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 automating manufacture of at least one component of a dental restoration selected from the group consisting of a crown, multi-tooth unit, bridge, coping, crown coping, core, abutment and infrastructure, the method comprising the steps of:
 obtaining digital job information for a plurality of the components to be manufactured at one or more computer automated machines;   manufacturing the plurality of components by the one or more computer automated machines;   memorializing an identity of at least one component during manufacturing; and   maintaining a record of the identity of the at least one component.   
     
     
         2 . The method as claimed in  claim 1  wherein the step of maintaining a record of the identity of the component includes placing a unique identification mark in association with the component. 
     
     
         3 . The method as claimed in  claim 2  wherein the unique identification mark is placed on the component. 
     
     
         4 . A method of design for mass custom manufacturing of dental crowns and/or 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 an electronic file based upon the information, the electronic file including a virtual model and a virtual final external shape of a tooth of a restoration within the virtual model for the patient;   deconstructing from the file to design at least one component of the restoration.   
     
     
         5 . The method as claimed in  claim 4  further comprising the step of manufacturing said at least one component based upon data from said file. 
     
     
         6 . The method as claimed in  claim 5  wherein the at least one component is made from an end state material or through a controllable process that results in the material assuming end state properties. 
     
     
         7 . The method as claimed in  claim 5  wherein said step of manufacturing comprises the step of controlling multiple manufacturing machines simultaneously, multiple machines sequentially, one or more machines contemporaneously, or a single machine sequentially, by a central control system. 
     
     
         8 . The method as claimed in  claim 7  further comprising the step of learning adaptively from said prior creating, deconstruction and/or manufacturing steps. 
     
     
         9 . The method as claimed in  claim 7  wherein said central control system is capable of contemporaneously manufacturing two or more components on two or more different machines. 
     
     
         10 . The method as claimed in  claim 7  wherein said central control system controls machines for manufacturing any dental restoration such as implant abutments, temporary crowns, cores/copings, crown molds and crowns. 
     
     
         11 . The method as claimed in  claim 4  wherein said deconstructing step comprises the step of:
 removing virtually a thickness of an outer component from the final external shape of the restoration to determine a shape and orientation of an inner component. 
 
     
     
         12 . A system of design for mass custom manufacturing of a restoration including crowns and/or 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 file based upon data from said data input device, said file containing data regarding at least one component of the restoration.   
     
     
         13 . The system as claimed in  claim 12  further comprising:
 a central controller; and 
 at least one manufacturing machine controlled by said central controller. 
 
     
     
         14 . The system as claimed in  claim 13  wherein said at least one machine comprises multiple machines controlled simultaneously and/or contemporaneously. 
     
     
         15 . The system as claimed in  claim 13  wherein said at least one machine comprises a single machine controlled sequentially. 
     
     
         16 . The system as claimed in  claim 13  wherein said central controller enables control of a CAD system for creating said file. 
     
     
         17 . The system as claimed in  claim 13  wherein said central controller enables control of a robot capable of enabling unloading finished pieces from said machines. 
     
     
         18 . The system as claimed in  claim 17  where said robot is further capable enabling of loading and unloading raw materials, packages/boxes with models, and models. 
     
     
         19 . The system as claimed in  claim 13  wherein said central controller enables updates to a design file in a CAD system that creates said file. 
     
     
         20 . The system as claimed in  claim 12  wherein said data input device comprises a scanning system. 
     
     
         21 . The system as claimed in  claim 20  wherein said scanning system is utilized to scan a model or impression of the patient's mouth, said model or impression being representative of the condition of the patient's mouth.