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Updated: May 22, 2026

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Rapid tooling method for soft customized removable oral appliances.

Mika Salmi1, Jukka Tuomi, Rauno Sirkkanen

  • 1Department of Industrial Engineering and Management, BIT Research Centre, Aalto University, School of Science, Espoo, Finland.

The Open Dentistry Journal
|May 23, 2012
PubMed
Summary

This study introduces a novel rapid tooling method for creating custom orthodontic appliances. This technique offers an accurate and potentially more comfortable alternative to traditional methods.

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Area of Science:

  • Biomaterials Engineering
  • Orthodontics
  • Manufacturing Technology

Background:

  • Traditional oral appliances rely on alginate impressions and wax registrations.
  • Customization is key for effective and comfortable oral appliance therapy.
  • Existing methods can be time-consuming and may lack precision.

Purpose of the Study:

  • To describe the manufacturing process of customized oral appliances using a novel rapid tooling method.
  • To evaluate the accuracy and feasibility of this new technique.
  • To assess patient adaptation to the custom-made appliance.

Main Methods:

  • A patient undergoing orthodontic treatment was selected as a study subject.
  • Dental arches were digitized and virtually corrected using computer software.
Keywords:
Additive manufacturingcomputer-aided design (CAD)computer-aided manufacturing (CAM)oral applianceorthodontics.rapid prototyping

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  • Additive manufacturing (stereolithography) created a mold from Somos ProtoGen O-XT 18420 material.
  • Silicone was used as the casting material for the final appliance.

    • Main Results:

    • A customized soft orthodontic appliance was successfully fabricated using the rapid tooling method.
    • The accuracy of the manufacturing process was found to be adequate.
    • Two appliance versions with varying orthodontic forces were produced.

    Conclusions:

    • The rapid tooling method provides a viable technique for manufacturing accurate, customized soft orthodontic appliances.
    • This approach may offer advantages over conventional fabrication methods.
    • Further research can explore broader applications and long-term patient outcomes.