System and method for manufacturing a dental prosthesis and a dental prosthesis manufactured thereby

Abstract

A dental prosthesis is made by externally machining successive layers of wax, each of which is formed on a previous prosthesis layer and/or on a coping. Each wax layer is used to form a mold in situ over the previous prosthesis layer/coping, and the appropriate prosthesis material is cast or otherwise molded to conform to the wax layer by the mold.

1 . (canceled) 
     
     
         2 . A system for producing a dental prosthesis for a patient, comprising:
 one or more processors comprising instructions that when executed, cause the system to:
 receiving a first three-dimensional scan, wherein the first three-dimensional scan comprises data of a dental site targeted for restoration; 
 receiving a second three-dimensional scan, wherein the second three-dimensional scan comprises data of a crown; 
 designing a geometry of a dental prosthesis for the dental site based at least in part on the first three-dimensional scan and the second three-dimensional scan, wherein the dental prosthesis is configured to be fit into the dental site; 
 generating a mold for forming the dental prosthesis based on the determined design. 
   
     
     
         3 . The system of  claim 2 , wherein designing the geometry of the dental prosthesis comprises comparing the first three-dimensional scan to the second three-dimensional scan. 
     
     
         4 . The system of  claim 2 , wherein data of the crown comprises data for a crown at the dental site. 
     
     
         5 . The system of  claim 2 , wherein data of the crown comprises data for a crown opposite to the dental site on the patient's arch. 
     
     
         6 . The system of  claim 5 , wherein designing the geometry of the dental prosthesis comprises providing a lateral inversion of the data of the crown. 
     
     
         7 . The system of  claim 2 , wherein designing the geometry of the dental prosthesis comprises modifying the second three-dimensional scan data. 
     
     
         8 . The system of  claim 7 , wherein modifying the second three-dimensional scan data is performed interactively. 
     
     
         9 . The system of  claim 7 , wherein the second three-dimensional scan data is modified to provide adequate clearance relative to adjacent teeth. 
     
     
         10 . The system of  claim 7 , wherein the second three-dimensional scan data is modified to provide adequate occlusion with opposing teeth. 
     
     
         11 . The system of  claim 2 , wherein designing the geometry of the dental prosthesis comprises defining maximum dimensions for the dental prosthesis and limiting a volume of the designed dental prosthesis to fit within the defined maximum dimensions. 
     
     
         12 . A system for producing a dental prosthesis for a patient, comprising:
 one or more processors comprising instructions that when executed, cause the system to:
 receiving a first three-dimensional scan, wherein the first three-dimensional scan comprises data of a dental site targeted for restoration, wherein the dental site spans a plurality of adjacent teeth; 
 designing a geometry of a dental prosthesis for the dental site based at least in part on the first three-dimensional scan, wherein the dental prosthesis is configured to be fit along the plurality of adjacent teeth; and 
 generating a mold for forming the dental prosthesis based on the determined design. 
   
     
     
         13 . The system of  claim 12 , wherein designing the geometry of the dental prosthesis is based at least in part on a library of 3D spatial profiles. 
     
     
         14 . The system of  claim 12 , wherein the geometry of the dental prosthesis is designed to fit on at least two dental copings. 
     
     
         15 . The system of  claim 12 , wherein designing the geometry of the dental prosthesis comprises comparing the first three-dimensional scan to a second three-dimensional scan; wherein the second three-dimensional scan comprises data of a crown. 
     
     
         16 . The system of  claim 15 , wherein the second three-dimensional scan comprises data for a crown at the dental site. 
     
     
         17 . The system of  claim 15 , wherein the second three-dimensional scan comprises data for a crown opposite to the dental site on the patient's arch. 
     
     
         18 . The system of  claim 17 , wherein designing the geometry of the dental prosthesis comprises providing a lateral inversion of the data of the crown. 
     
     
         19 . The system of  claim 12 , wherein designing the geometry of the dental prosthesis comprises modifying a digital 3D spatial profile of the dental prosthesis manually. 
     
     
         20 . The system of  claim 12 , wherein designing the geometry of the dental prosthesis comprises modifying a digital 3D spatial profile of the dental prosthesis interactively. 
     
     
         21 . The system of  claim 12 , wherein designing the geometry of the dental prosthesis comprises defining maximum dimensions for the dental prosthesis and limiting a volume of the designed dental prosthesis to fit within the defined maximum dimensions.