Artificial Intelligence in the Design and Optimization of Orthodontic Materials: A Clinical Perspective on Current...

Artificial intelligence (AI) has transformed orthodontic diagnosis, yet its application to orthodontic materials science remains critically underexplored. This perspective identifies and characterizes the AI-materials integration gap as the central unresolved problem in digital orthodontics: AI-optimized treatment plans are currently executed through empirically selected materials whose mechanical behavior is never modeled by the planning system. We examine four domains where this gap is consequential: thermoplastic aligner polymers (PETG vs. TPU), where supervised ANNs can predict force decay from polymer composition; NiTi archwire alloys, where Bayesian optimization and Gaussian process regression are accelerating alloy design; additive manufacturing of orthodontic devices, where supervised ML reduced print-parameter optimization burden in a 2025 five-variable surface roughness study; and AI-driven biological response prediction, where FEA-surrogate neural networks reduced biomechanical computation from minutes to milliseconds per patient query. A scoping review of clear aligner AI identified 41 studies-none addressing aligner material properties as a primary outcome. We argue that closing the AI-materials gap requires standardized open material-performance datasets; FEA-surrogate models integrating polymer stiffness as a treatment-planning input; patient-specific digital twins with defined material, mechanical, and biological parameter layers; and federated learning infrastructure spanning clinics and manufacturers.