EP1460963A1

EP1460963A1 - Arrangement for producing a three-dimensional body made of bone-compatible and/or tissue-compatible material, and device and use of the body

Info

Publication number: EP1460963A1
Application number: EP02793688A
Authority: EP
Inventors: Carina Berggren
Original assignee: Nobel Biocare AB
Current assignee: Nobel Biocare Services AG
Priority date: 2001-12-28
Filing date: 2002-12-19
Publication date: 2004-09-29
Also published as: WO2003061513A1; SE521944C2; SE0104447L; SE0104447D0

Abstract

In an arrangement for producing a three-dimensional body, preferably made of titanium, a computer-based first apparatus is used to identify and simulate the body in connection with a given implantation situation, and a second apparatus is used to produce a model or die as a function of the identification and simulation. A third apparatus comprises a unit for high-velocity flame spraying of the material in powder form via a nozzle. Movement-controlling members are also included for controlling the nozzle and/or members supporting the model or die. The unit is arranged to apply coating layers to the die via the nozzle during simultaneous movement control of the nozzle and/or the supporting member. The layer coating can be controlled or emanate from the first apparatus and/or the second apparatus to form the body. The invention also relates to a device and a use. By means of what is proposed, a novel way of building up three-dimensional bodies is obtained, while maintaining earlier requirements in terms of precision and strength.

Description

Arrangement for producing a three-dimensional body made of bone-compatible and/or tissue-compatible material, and device and use of the body.

The present invention relates to an arrangement for producing a three-dimensional body made of bone- compatible and/or tissue-compatible material, preferably meaning titanium in this case. The arrangement uses a computer-based first apparatus to identify and simulate the body in connection with a given implantation situation. It also includes a second apparatus for producing a model or die as a function of the identification or simulation. The invention also relates to a device in the form of a three-dimensional body made of bone-compatible and/or tissue-compatible material, and to a use of such a body.

It is already known to produce three-dimensional bodies (dental crowns, implants, etc.) with the aid of a scanned implantation situation, simulation function, model production etc . , and to control the production of said body or product from a blank which is machined, for example mechanically and/or electroche ically, in order to produce the final product. In this connection, reference may be made to the arrangements and methods used and published by PROCERA AB, Sweden. Reference is also made to the patent applications previously filed and the patents obtained by the same Applicant as is filing the present patent application. Thus, for example, it is proposed to use support members which can be controlled in rotation and in the vertical direction relative to a scanner and function member. The scanning can be done optically or mechanically, with camera equipment, etc. It is also known to use computed tomography in connection with an analysis function which is carried out with the aid of computer equipment, in which the respective implantation situation can be simulated and analyzed together with the detected and desired product. It is also already known to produce dental products using powder material which is bone-compatible and/or tissue-compatible. The powder material is compacted in the known apparatuses with pressing and sintering functions.

In purely general terms it is known to use so-called high-velocity flame spraying (HVOF) of powder. In known cases, pump axles, piston rods, rotor axles, rollers, etc., are coated with layers. The apparatus in question can use oxygen gas and a combustible gas or liquid which, under high pressure, are driven into a combustion chamber where the gases are mixed and atomized. When the mixture is combusted, the pressure increases very rapidly and the gas can flow out from the chamber. The powder is introduced into the hot jet stream and also accelerates this very quickly to supersonic speed. The outflowing molten powder material forms the layer or layers in question. The flame temperatures can be ca. 2800°C and the particle velocity can be ca. 800 m/s. See fact sheet issued by IVF.

In production of three-dimensional bodies, for example dental crowns, implants, etc., there is a need for new arrangements and methods previously used in the field to be improved or replaced from the point of view of efficiency and economics, while maintaining or enhancing the required production precision and effectiveness. In the production of products in a dental context, individually adapted products must be produced which are to be made in one or more copies, which further increases the requirements in terms of cost and efficiency. It is important that the new principles of production are able to employ existing aids in connection with the use. Thus, for example, it is important that the new arrangements can be included in and used together with computer-based aids, computed tomography, X-rays, modern scanning aids, etc. The main object of the present invention is to solve these problems inter alia.

The feature which can principally be regarded as characterizing the arrangement mentioned in the introduction is, inter alia, that a third apparatus is arranged with a unit for high-velocity flame spraying of the material in powder form via a nozzle and movement-controlling members for controlling the nozzle and members supporting the model or the die. The arrangement is further characterized in that the unit is arranged to apply coating layers to the model or die via the nozzle during simultaneous movement control of the nozzle and/or said supporting members, and in that the layer coating can be controlled or emanate from the first apparatus and/or the second apparatus to form the body.

In further developments of the inventive concept, it is proposed, inter alia, that variations in the wall thickness and outer configurations can be effected by means of control of the high-velocity flame and/or the mutual movements between nozzle and body. Further developments of the inventive concept are set out in the attached dependent claims concerning the arrangement .

A device according to the invention can principally be regarded as being characterized by the fact that it comprises a number of layers situated on one another and applied by high-velocity flame spraying of the material in powder form. Said layers in the hardened state are preferably self-supporting from the point of view of strength.

A use according to the invention is principally characterized by the fact that an apparatus for high- velocity flame spraying of the material in powder form is used in order to apply layers to the die or model during movement of a nozzle in the apparatus and/or the die or the model or a member supporting this.

By means of what has been proposed above, a new way is found of producing three-dimensional products for dentistry and/or for the human body, or blanks for such products. The model or die is coated with thin layers of molten titanium powder which are applied on top of one another until the desired body shape has been obtained. With the layers in the hardened state, the body can be removed from the die and, in one embodiment, can be used directly.

A presently proposed embodiment of an arrangement, a device and a use will be described below with reference to the attached drawing in which

Figure 1 shows, diagrammatically and in block form, an arrangement for producing a body, or a blank for a body, by means of high-pressure flame spraying, preferably of titanium powder, and

Figure 2 shows, in a greatly enlarged view, a number of layers which are arranged on a die or model and which have been applied to it by means of said high-pressure flame spraying.

In Figure 1, a first apparatus is indicated by 1, a second apparatus is indicated by 2, and a third apparatus is indicated by 3. The interfaces between the apparatus can be arranged in different suitable ways.

The first apparatus which can be of a type known per se comprises scanning equipment 4 which is used to determine a dental situation on a patient 5. The scanning function can be of a type known per se, and the determination of the implantation situation in question can thus be effected with the aid of a model, by optical scanning, imaging by means of a camera, etc. The imaging is represented by an arrow 6, and the result obtained from the imaging, indicated by an arrow 7, is delivered to equipment which detects the imaging and is of the type which can convert the image to digital information, which is represented by 9. In a computer appliance 10, the digital information 9 can be received and an analysis can be performed by a user 11 in interaction between the user and the computer appliance. The computer appliance can be provided with control elements 10a, speech-activated control members, etc., by means of which the user performs the analysis work. The analysis function can also include help functions such as computed tomography carried out with equipment 12 provided for this purpose, or a library 13 which contains empirical information. Information from such external sources 12, 13 has been indicated by 14 in Figure 1.

The analysis function by means of the apparatus 1 can result in an information transmission signal 15 which is intended for a production unit 16 included in the apparatus 2. The production unit can serve a number of detection and analysis sites in accordance with the above, and a further set of the apparatus in question has been indicated by 4' and 10'. The different first apparatuses can be sited at different dentists, dental technicians, etc. The produced template or die can be transferred manually, for example by post, transport, etc. Alternatively, information signals 18 (files) can be transmitted to transmission units 19, 20, 21, etc. which are each assigned their own function or their information/files. The production unit is connected to the first apparatus via a first bus connection 22, and the units 19, 20, 21 are connected to the production unit 16 via a second bus connection 22. The units 19, 20 and 21 can also be connected to an outward bus connection, here designated the third bus connection 23. First and second control units can be connected to the last-mentioned bus connection. The file information 18 on the second bus connection 22 can be divided up into different information parts or files 18a, 18b and 18c. The control units 24 and 25 can take in control information from one or more of said units 19, 20 and 21, and the control unit 24 is thus able to receive information or file 26, and the control unit 25 is able to receive information or file 27. The last-mentioned information/files 26 and 27 can emanate directly from the first apparatus, as has been indicated by broken lines 28. The information/files 26 and 27 in question relate to control functions or control data for an apparatus for high-velocity flame spraying of powder, to which the control unit 24 is connected or forms part of in a manner known per se. As a function of the control information 26, the control unit can control a nozzle 29 forming part of the apparatus. The control can effect rotational or tilting movements about or of its longitudinal axis 30. The rotation movement is indicated by 31, and the tilting movement by α. Alternatively, or in addition to this, the nozzle can also be displaced in parallel in the directions of the arrows 32 and 33 and in directions in toward and out from the plane of Figure 1. The actuation function from the control unit 24 is shown by an arrow 34. Correspondingly, by means of control signals 35, the control unit can act on a support member 36 for a model or die 37. The support member/model/die can thus be rotated about a vertical axis 38, the rotation arrows having been indicated by 39. The member 36/model/diθ' can also be displaced in the vertical direction 40 and side directions 41, 42. The information or file 27 and the information 35 issuing from the control unit 25 can also relate to the structure of the model or die, which applies in cases where the produced model is to be transmitted by electrical information/files. The information can alternatively be transmitted on diskettes.

As regards the function of the apparatus for high- velocity flame spraying, this will not be described in detail here because equipment which is known per se can be used. As can be seen from Figure 1, the nozzle comprises an air cap and channels for compressed air, oxygen, propane, or oxygen-hydrogen. There is also a central channel for the powder material in question, which in the present case is titanium powder applied with the aid of carrier gas in nitrogen. The nozzle thus comprises inner and outer nozzles for the above components. Said information signals 34 to the nozzle can also include information on the quantities of the various components and the powder, the flame temperature, the particle velocities, etc. Depending on the controlled flame-spraying function and movement function, molten particles 43a are directed toward the outer surface 37a of the model/die or to layers which have already been sprayed onto this surface. In accordance with the concept of the invention, the nozzle and the model/die execute mutual movements as a function of said controls, during which molten powder 43a included in a high-velocity flame coats the surface 37a which is moving relative to it. In this way, layers can gradually be built up on the surface. In accordance with the concept of the invention, a number of thin layers located on top of one another are to be applied to the surface 37a.

Figure 2 shows, in a greatly enlarged view, three layers 44, 45 and 46 arranged on top of one another.

When the layers have hardened, the body thus formed by the layers 44, 45, 46, etc., is removed from the model or die 37. It can be removed in a manner known per se and this is represented by 47 in Figure 1.

In accordance with the above, a body (blank) is obtained which is self-supporting from the point of view of strength and which can be used for dental products or for other products for the human body. By means of said controls 34 and 35, the body can be structured with very great precision, which is important in a dental context in connection with dental crowns, spacers, etc. The third apparatus can be controlled in such a way as to give the desired outer configuration directly, which in certain situations means that the body does not have to undergo any after- treatment. The body thus acquires good properties from the point of view of precision and the point of view of strength.

By means of the present invention, it is thus possible to use equipment for high-velocity flame spraying of powder, made from bone-compatible and/or tissue- compatible material, simultaneously with a movement function in accordance with the above. As an alternative to titanium powder, it is possible to use powder made from gold alloy, steel, etc. In the case of titanium powder, pure powder (99.99%) with relatively small particles, for example Wah Chang HP (or CP) -325 Mesh T080014 (010607) , is used. Said bus connections can be data and/or telecommunication links and can include or consist of public networks, the Internet, etc. The model or template can be produced in the unit 16 or at another site which receives production information from the unit 16, see Figure 1.

The invention is not limited to the embodiment described above, and instead it can be modified within the scope of the attached patent claims and the inventive concept.

Claims

PATENT CLAIMS

1. An arrangement for producing a three-dimensional body made of bone-compatible and/or tissue- compatible material, preferably of titanium, using a computer-based first apparatus to identify and simulate the body in connection with a given implantation situation, and a second apparatus to produce a model or die as a function of the identification and simulation, characterized by a third apparatus which comprises a unit for high- velocity injection-molding of the material in powder form via a nozzle, and movement-controlling members for controlling the nozzle and members supporting the model or die, and in that the unit is arranged to apply coating layers to the model or die via the nozzle during simultaneous movement control of the nozzle and/or said supporting member, and in that the layer coating can be controlled or emanate from the first apparatus and/or the second apparatus to form the body.

2. The arrangement as claimed in patent claim 1, characterized in that variations in the wall thickness and outer configurations can be effected by means of control of the high-velocity flame and/or the mutual movements between nozzle and body.

3. The arrangement as claimed in patent claim 1 or 2, characterized in that the model or die is arranged for application of a number of thin layers from the nozzle, and in that the applied thin layers form the framework of the body.

4. The arrangement as claimed in patent claim 3 , characterized in that the body or framework formed by the thin layers is arranged to be separated from the model or die when the layers have hardened.

5. The arrangement as claimed in patent claim 4, characterized in that the separated body or framework can be used directly in the implantation situation without further after-treatment or with only minimal after-treatment.

6. The arrangement as claimed in any of the preceding patent claims, characterized in that titanium powder has a substantially high purity, for example a purity of 99.99%.

7. The arrangement as claimed in any of the preceding patent claims, characterized in that the titanium powder has a relatively small particle size.

8. A device in the form of a three-dimensional body made of bone-compatible and/or tissue-compatible material, preferably titanium, characterized in that it comprises a number of layers situated on one another and applied by high-velocity flame spraying of the material in powder form.

9. The device as claimed in patent claim 8, characterized in that the layers in the hardened state are self-supporting from the point of view of strength.

10. Use of a device in the form of a three-dimensional body made of bone-compatible and/or tissue-compatible material, preferably titanium, characterized in that an apparatus for high-velocity flame spraying of the material in powder form is used in order to apply layers to the die or model during movement of a nozzle in the apparatus and/or the die or the model or a member supporting this.