Proof-of-Concept Digital-Physical Workflow for Clear Aligner Manufacturing
Shih-Hao Huang1, I-Chiang Chou2,3, Mayur Jiyalal Prajapati4
1Graduate Institute of Manufacturing Technology, National Taipei University of Technology, Taipei City 10608, Taiwan.
Dentistry Journal
|October 28, 2025
Summary
This 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.
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.
