Sustainability

The most widely used technology for producing orthodontic aligners, known as thermoforming, was developed in 1997. This method requires a 3D dental model, which is then thermoformed using plastic made from various types of polymers to create the aligner.

​

The traditional production workflow includes several steps: receiving the intraoral 3D scan, digitally planning the treatment using CAD software, printing resin prototypes, and finally thermoforming and trimming the aligners.

​

One serious issue with thermoformed aligners is the massive number of resin dental models produced annually—both in-house and by manufacturers—for aligner fabrication. These resin models are not recyclable, placing a significant burden on an already stressed environment.

​

Recent advances in orthodontics have introduced a disruptive innovation: direct aligner 3D printing using shape-memory polymers. This technology offers numerous advantages over the traditional thermoforming process, including:

​

🔹 Environmental Impact

The buildup of non-recyclable dental models represents a serious environmental concern. Directly 3D-printed aligners eliminate the need for printed models altogether. Additionally, the materials used in this method are more environmentally friendly. The number of aligners required to achieve tooth movement is up to three times lower compared to conventional methods. Since aligners are typically replaced every 14 days, the ecological footprint becomes a relevant issue. Direct printing reduces production and environmental costs alike. It consumes less energy, cuts carbon emissions, and eliminates the plastic waste produced by trimming thermoformed aligners. The carbon footprint of a single thermoformed aligner is approximately 4 kg of CO₂, while that of a directly printed aligner is only 1.8 kg.

​

🔹 Efficiency

By eliminating steps such as resin model printing and thermoforming, direct 3D printing streamlines the production process. This enables faster delivery of aligners to patients.

​

🔹 Cleaner Work Environment

Thermoforming generates dust, contributing to a messier office and potential health risks to staff. In contrast, 3D-printed aligners are manufactured in clean, dust-free environments.

​

🔹 Accuracy

Printed aligners offer superior adaptation compared to thermoformed versions made from plastic film. Precise fit is essential for predictable and effective treatment outcomes.

​

🔹 Uniform Thickness

Printed aligners maintain consistent thickness throughout, delivering uniform force to all teeth. Thermoformed aligners often lose thickness during the molding process, affecting force delivery.

​

🔹 Versatility

Printed aligners allow for customized thickness in specific areas. Using CAD software, additional material can be applied only where needed, enhancing treatment flexibility and control.

​

Direct aligner printing with shape-memory polymers represents a major leap forward in clear aligner therapy. This technology has the potential to reduce both treatment costs and environmental impact.

​

Consumers aren’t necessarily looking for the largest aligner brand—they’re seeking effective treatment and the benefits it provides. And when it comes to benefits, this technology delivers plenty.