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Updated: Jun 4, 2026

Force System with Vertical V-Bends: A 3D In Vitro Assessment of Elastic and Rigid Rectangular Archwires
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Published on: July 24, 2018

Biomechanical force profiles and force decrease of direct printed versus thermoformed aligners with different

Bernhard Wiechens1, Philipp Meyer-Marcotty2, Emilia von Waldthausen2

  • 1Department of Orthodontics, Universitätsmedizin Göttingen, Göttingen, Germany. bernhard.wiechens@med.uni-goettingen.de.

Progress in Orthodontics
|June 3, 2026
PubMed
Summary
This summary is machine-generated.

Direct-printed aligners (DPA), especially those with a garlanded trimline (DPAG), exhibit lower and more controlled forces compared to thermoformed aligners (TFAS). DPAs demonstrate a significant early force decrease, suggesting improved biomechanical profiles.

Keywords:
Direct printed alignersForce decreaseGingival margin designOrthodonticsThermoformed alignersVertical force

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Area of Science:

  • Orthodontics
  • Biomaterials Science
  • Dental Mechanics

Background:

  • Evaluating biomechanical force profiles of orthodontic aligners is crucial for treatment efficacy.
  • Comparing thermoformed aligners (TFA) with direct-printed aligners (DPA) with varying gingival trimlines is essential for understanding force delivery.

Purpose of the Study:

  • To compare the biomechanical force profiles of thermoformed aligners (TFAS) and direct-printed aligners (DPAS, DPAG) during simulated tooth movement.
  • To analyze the influence of different gingival trimlines on aligner force delivery.

Main Methods:

  • An in vitro study utilized a 3D-printed model simulating 0.25 mm bodily translation of a maxillary central incisor.
  • Forces (Fx, Fy, Fz) were measured using a multi-axis force sensor for three aligner types over 60 minutes.
  • Analysis included vertical, transverse, and sagittal force components and their decrease, characterizing initial force delivery and early stress relaxation.

Main Results:

  • Thermoformed aligners (TFAS) generated the highest sagittal forces (Fx: -0.70 N) during facial translation.
  • Direct-printed aligners with a garlanded trimline (DPAG) showed significantly lower forces (Fx: -0.25 N) for facial movement and controlled forces (p < .001) for palatal movement.
  • Vertical forces (Fz) were higher in TFAS (-0.10 N), while DPAs exhibited near-zero or slightly extrusive forces (p < .001).

Conclusions:

  • Direct-printed aligners (DPA), particularly DPAG, demonstrate lower sagittal forces and reduced vertical force components in vitro.
  • DPAs exhibit a pronounced early force decrease within the initial 60 minutes.
  • Further research is needed to assess aligner force behavior beyond the initial seating phase.