Dental labs produce custom aligners using 3D printing by first gathering precise 3D scans of a patient’s teeth. Instead of relying on conventional impression trays, dentists use high-resolution intraoral scanners to capture comprehensive oral topographies of the mouth. These virtual tooth representations are then securely uploaded to the dental laboratory, where orthodontic specialists utilize AI-enhanced treatment design tools to map out the gradual tooth movement over the course of treatment. The software divides the entire treatment into discrete phases, with each step representing a unique stage of tooth positioning.

Once the treatment plan receives dental practitioner sign-off, the lab optimizes the print-ready models for 3D printing. Using a dental-specific stereolithography printer, the lab produces a a sequence of anatomical replicas, each corresponding to a single treatment stage. These models are milled using medical-grade photopolymer, chosen for its structural integrity and biocompatibility to ensure accurate tooth replication.

After printing, the lab positions a flexible clear polymer film over each model. Through a process involving precision heat-sealing under vacuum pressure, the material molds flawlessly around each tooth position to create a patient-specific orthodontic tray. Each aligner is then hand-finished and buffed for comfort to ensure maximum patient compliance. The aligners undergo multi-point accuracy checks before being labeled and sealed and ارتودنسی_شفاف delivered to the provider for patient distribution.

This entire workflow enables unparalleled customization while maintaining batch-to-batch reliability. Since every aligner is directly printed from a digital blueprint, variation between units is virtually eliminated, and quick revisions can be implemented if treatment deviates. Additionally, 3D printing replaces weeks of manual work with hours of automation, allowing patients to begin treatment faster. As dental lab innovations continue, laboratories are enhancing this process to deliver higher-precision, faster, and better-tolerated treatments.