title: Fabrication of a resin appliance with alloy components using digital technology without an analog impression.
abstract: The aim of this study was to fabricate a resin appliance incorporating "wire" components without the use of an analog impression and dental casts using an intraoral scanner and computer technology to build the appliance. This unique alignment of technology offers an enormous reduction in the number of fabrication steps when compared with more traditional methods of manufacture. The prototype incorporated 2 Adams clasps and a fitted labial bow. The alloy components were built from cobalt-chromium in an initial powdered form using established digital technology methods and then inserted into a build of a resin base plate. This article reports the first known use of computer-aided design and additive manufacture to fabricate a resin and alloy appliance, and constitutes proof of the concept for such manufacturing. The original workflow described could be seen as an example for many other similar appliances, perhaps with active components. The scan data were imported into an appropriate specialized computer-aided design software, which was used in conjunction with a force feedback (haptic) interface. The appliance designs were then exported as stereolithography files and transferred to an additive manufacturing machine for fabrication. The results showed that the applied techniques may provide new manufacturing and design opportunities in orthodontics and highlights the need for intraoral-specific additive manufacture materials to be produced and tested for biocompatibility compliance. In a trial, the retainer was fitted orally and judged acceptable by the clinician according to the typical criteria when placing such appliances in situ.
authors.affiliation: Assistant professor, Jordan University of Science and Technology, Irbid, Jordan. Electronic address: naalmortadi@just.edu.jo.
authors.forename: Noor
authors.initials: N
authors.lastname: Al Mortadi
authors.affiliation: Orthodontist, Cardiff University Dental School, Heath Park, Cardiff, United Kingdom.
authors.forename: Quentin
authors.initials: Q
authors.lastname: Jones
authors.affiliation: Senior lecturer, National Centre for Product Design and Development Research, Cardiff, United Kingdom.
authors.forename: Dominic
authors.initials: D
authors.lastname: Eggbeer
authors.affiliation: Head of surgical and prosthetic design, Cardiff School of Health Sciences, Cardiff Metropolitan University, Cardiff, United Kingdom.
authors.forename: Jeffrey
authors.initials: J
authors.lastname: Lewis
authors.affiliation: Professor, Cardiff School of Health Sciences, Cardiff Metropolitan University, Cardiff, United Kingdom.
authors.forename: Robert J
authors.initials: RJ
authors.lastname: Williams
mesh_terms: D002858:Chromium Alloys / Q000737:chemistry*; D003188:Composite Resins / Q000737:chemistry*; D017076:Computer-Aided Design; D016734:Dental Clasps; D003761:Dental Impression Technique; D003764:Dental Materials / Q000737:chemistry*; D006801:Humans; D021621:Imaging, Three-Dimensional / Q000379:methods; D016382:Orthodontic Appliance Design; D018704:Orthodontic Retainers; D009969:Orthodontic Wires; D013674:Technology, Dental; D014584:User-Computer Interface; D057188:Workflow
chemical_list: D002858:Chromium Alloys; D003188:Composite Resins; D003764:Dental Materials