Properties enhancements of clear aligners after the laser surface texturing modification on thermoplastic...

Balancing the aesthetic and mechanical effects remains challenging in terms of attachments. This study proposed a strategy by introducing laser surface texturing in clear aligners fabrication to enhance the retention and grip of clear aligners and minimize the size of attachments.

A grid pattern with a spacing of 1 mm on the surface of thermoplastic polyurethane substrate was textured using a CO₂ laser. We used LST-modified TPU to fabricate aligners and evaluated its mechanical and surface properties.

TPU after laser surface texturing exhibited increased roughness, and therefore enhanced the retention and gripping force of LST-modified clear aligners. Although the average transmittance of the LST-modified TPU was 2.32% lower, LST had little negative effect on aesthetic of aligners.

Laser surface texturing, as a novel auxiliary approach in aligners fabrication, has the potential to enhance mechanical properties such as roughness, retention and force delivery of TPU-fabricated clear aligners.

The mechanical enhancement of LST-modified clear aligners could have a better control on teeth movements and reduce the sizes of attachments without sacrificing their mechanical effect, helping to balance the aesthetics and mechanic effects of attachments.