Numerical biomechanical finite element analysis of different trimming line designs of orthodontic aligners: An in...

A finite element model was used to investigate the effect of different designs and thicknesses of orthodontic aligner margins on their biomechanical behavior.

A three-dimensional data set of an upper jaw was imported into the 3-matic software. The upper right central incisor tooth (Tooth 11) was separated from the remaining model, and its periodontal ligament and surrounding bone were designed. Aligners were designed with four different trimming lines (scalloped, straight, scalloped extended, straight extended), each with four different thicknesses (0.3, 0.4, 0.5, and 0.6 mm). The models were imported into a finite element package (Marc/Mentat). A linear elastic constitutive material model was applied. A facial 0.2 mm bodily malalignment of tooth 11 was simulated.

The maximum resultant force was in the range of 1.0 N to 2.2 N. The straight trimming designs deliver higher resultant forces compared with scalloped trimming designs. Increasing the aligner thickness and/or extending the aligner edge beyond the gingival line leads to an increase in the resultant force. All designs showed an uneven distribution of the normal contact forces over the tooth surface with a predominant concentration toward the cervical third and distal third, particularly with the extended trimming designs. All designs showed uncontrolled tipping of the tooth.

Based on the current model outcomes, the use of a straight extended trimming line design for aligners is favored because of its positive impact on force distribution and, consequently, the control of tooth movement.

These findings provide aligner companies and orthodontists a valuable biomechanical evidence and guidance to enhance control over tooth movement and therefore optimize treatment outcomes. This can be achieved by trimming the edges of aligners with a straight extended design and selecting the appropriate aligner thickness.