Excellence in Every Step
In order to manufacture an outstanding appliance it is necessary to combine advanced ordering, design, and manufacturing technologies to create the 100% customized and highly precise Incognito™ Appliance System. The following guide outlines this unique and highly-technical process.
The Incognito System fabrication process begins with an impression. Submit the impression, wax bite, and patients prescription via a Lab Order Form.
The laboratory uses the impression to create maloccluded models. They are the basis for the preparation of the physical and digital setup.
Take an impression of your first patient.
Put together the Lab Order Form, the impressions and the wax bite and send them to TOP-Service für Lingualtechnik GmbH (Laboratory).
The lab team creates a model of the malocclusion from the impression. This model is the basis for the preparation of the setup.
Since a bad impression/model could mean that the brackets do not fit the patient upon delivery, the model is checked for quality before moving through the rest of the process. Our specially trained Customer Care team confirms that 3M Unitek can deliver a quality product and provides support during the entire process, acting as the main contact for all treatment-related questions.
Regardless of the option - Manual or Digital Setup - highly qualified 3M Unitek technicians produce the setup according to the doctor's individual prescription and Andrews' Six Keys.
The digital design of the bracket relies exclusively on the setup scan. Customized bracket pads and bases are designed using the lingual surface of the digital model.
The height, width, torque and angulations of each bracket body are customized and assembled on the base in the optimal position, based on the unique prescription for each patient. Each wing is adjusted with the intent of optimizing comfort and tie-wing functionality, while each pad size is customized and designed to deliver optimal bond strength.
A rapid prototype process is used to print patterns of the digitally designed customized brackets. During the prototyping process, the customized brackets are made in an additive manner layer by layer. This method ensures that the subsequent casting process will be perfect.
Bracket models created in wax are embedded in molds and then cast in gold.
Once the gold brackets are separated from the casting channel, they are polished.
Cast » Barelled » Polished
Finally, the slot dimension is manually checked in every bracket and, if it doesn't meet the standard, a new bracket will be manufactured.
Customized archwire geometry is determined by the prescription and the CAD/CAM software.
Each steel and Beta Titanium wire in the sequence is designed based on the target occlusion and bent to the final result using robotic technology. The super elastic Unitek™ Nitinol wires are manually programmed and bent using heat and specialized plates.
As the last step, the trays are made on the malocclusion model, to make sure that the brackets are precisely and efficiently transferred to the patients mouth.
Therefore a 100% customized bonding tray is made based on the maloccluded model to transfer the brackets precisely and efficiently to the patient's mouth.
In the final step, all materials are checked against the order before shipping.
The final result, a 100% customized appliance system that includes brackets, archwires and bonding trays, is shipped to the orthodontist for treatment.