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Related Experiment Video

Updated: Jan 15, 2026

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A standardized protocol for clear aligner thickness measurement using a 3D-printed auxiliary device.

Peiqi Wang, Qingying Liu, Junyan Leng

    The Angle Orthodontist
    |October 15, 2025
    PubMed
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    A new 3D-printed device improves clear aligner thickness measurement accuracy. This auxiliary measurement method offers superior repeatability and operator independence for quality control.

    Area of Science:

    • Biomaterials Science
    • Dental Technology
    • Manufacturing Engineering

    Background:

    • Accurate measurement of clear aligner (CA) thickness is crucial for effective orthodontic treatment.
    • Current measurement methods lack reliability and standardization, impacting quality control and material research.

    Purpose of the Study:

    • To develop and validate a standardized protocol for clear aligner thickness measurement.
    • To enhance measurement reliability using a novel three-dimensional (3D)-printed auxiliary device.

    Main Methods:

    • 24 pairs of digital dental models were used to create 3D-printed physical models and thermoform clear aligners.
    • Customized measurement auxiliary devices (MADs) were designed and 3D-printed based on digital models.
    • Two operators measured clear aligner thickness using direct measurement (D-M) and auxiliary measurement (A-M) across three sessions.
    Keywords:
    CAD/CAMClear alignerMeasurement protocol

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    Last Updated: Jan 15, 2026

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    Main Results:

    • Auxiliary measurement (A-M) demonstrated superior intersession repeatability (ICC > 0.90) and agreement.
    • A-M showed higher interoperator reproducibility (ICCs > 0.75) compared to D-M (ICCs < 0.75).
    • Bland-Altman plots confirmed narrow limits of agreement and minimal outliers for A-M.

    Conclusions:

    • The 3D-printed auxiliary device protocol offers a precise and operator-independent method for clear aligner thickness measurement.
    • This standardized protocol serves as a valuable tool for quality control in clear aligner manufacturing.
    • The findings provide a foundation for future research in material advancement and design optimization for improved aligner functionality.