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Proof-of-Concept Digital-Physical Workflow for Clear Aligner Manufacturing.

Shih-Hao Huang¹, I-Chiang Chou^2,3, Mayur Jiyalal Prajapati⁴

¹Graduate Institute of Manufacturing Technology, National Taipei University of Technology, Taipei City 10608, Taiwan.

Dentistry Journal

|October 28, 2025

Summary

This summary is machine-generated.

This study presents a digital workflow for clear aligner manufacturing using 3D printing and simulations. This approach enhances aligner accuracy and predictability, reducing the need for adjustments in orthodontic treatments.

Keywords:

Polyflow additive manufacturing dentistry digital dental model finite element analysis thermoforming

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Area of Science:

Biomaterials Engineering
Orthodontic Technology
Digital Dentistry

Background:

Clear aligner therapy is a popular alternative to fixed orthodontics.
Variability in thermoforming and digital workflow validation hinder reproducibility.
Lack of standardized digital workflows limits clear aligner predictability.

Purpose of the Study:

To develop and validate a digital workflow for clear aligner manufacturing.
To integrate additive manufacturing (AM), thermoforming simulation, and finite element analysis (FEA).
To enhance the accuracy and predictability of clear aligner therapy.

Main Methods:

3D printing of dental models.
Thermoforming simulation and experimental validation using PETG sheets (0.5 and 0.75 mm).
Finite element analysis (FEA) for stress distribution and geometric accuracy assessment using CloudCompare v2.13.0.

Main Results:

Positive-pressure thermoforming significantly reduced geometric deviations (1.06 mm to 0.4 mm).
Thickness simulations showed good agreement with experimental data (<10% error).
FEA confirmed localized force transmission at the aligner-attachment interface.

Conclusions:

The proposed digital workflow enhances clear aligner consistency and accuracy.
Simulation-guided design and controlled thermoforming improve treatment predictability.
This framework can reduce the need for manual adjustments in orthodontic treatments.