Thermo-mechanical properties of 3D printed photocurable shape memory resin for clear aligners

Biocompatibility of variable thicknesses of a novel directly printed aligner in orthodontics

Direct printed aligners (DPAs) offer benefits like the ability to vary layer thickness within a single DPA and to 3D print custom-made removable orthodontic appliances. The biocompatibility of appliances made from Tera Harz TA-28 (Graphy Inc., Seoul, South Korea) depends on strict adherence to a standardized production and post-production protocol, including UV curing. Our aim was to evaluate whether design modifications that increase layer thickness require a longer UV curing time to ensure biocompatibility. Specimens with varying layer thickness were printed to high accuracy using Tera Harz TA-28 and the Asiga MAX 3D printer (Asiga SPS ™ technology, Sydney, Australia). UV curing durations were set at 20, 30 and 60 min. Cytotoxicity was evaluated using the AlamarBlue assay on human gingival fibroblasts. Cell viability decreased with increasing specimen thickness (significant for 2 mm [p < 0.001], 4 mm [p < 0.0001], and 6 mm [p < 0.01]) under the manufacturer-recommended 20-min UV curing. Extending the curing time did not improve cell viability. However, cell viability never decreased by more than 30%, meeting EN ISO 10993-5 standards for non-cytotoxicity. The standard 20-minute UV curing protocol ensures the biocompatibility and patient safety of Tera Harz TA-28 for material thicknesses up to 6 mm.

Study on the Antibacterial Properties and Optical Characteristics of Clear Orthodontic Aligners Coated With Zinc Oxide and Magnesium Oxide Nanoparticles

OBJECTIVES

This study aimed to evaluate and compare the antibacterial properties and optical characteristics of clear orthodontic aligners coated with zinc oxide (ZnO) and magnesium oxide (MgO) nanoparticles.

MATERIALS AND METHODS

In this experimental laboratory study, polyethylene terephthalate glycol (PETG) aligner samples were coated with nanoparticles of ZnO, MgO and a combination of both (ZnO + MgO). The surface coatings were analysed before and after stability testing using field emission scanning electron microscopy (FESEM). Colour changes and translucency were measured using a spectrophotometer, and the antimicrobial and antibiofilm properties were evaluated against Streptococcus mutans and Lactobacillus species. Statistical analysis was conducted using SPSS, with significance set at p < 0.05.

RESULTS

Significant statistical differences were found in the colour changes between the groups (p < 0.001), with the greatest change in MgO-coated aligners (0.94 ± 0.09), followed by ZnO + MgO (0.75 ± 0.05) and ZnO (0.5 ± 0.09). ZnO-coated aligners exhibited the highest translucency (47.6 ± 0.44) compared to MgO (45.07 ± 0.74) and ZnO + MgO (45.76 ± 0.7) (p = 0.002 and p = 0.026, respectively). Nanoparticle-coated aligners showed significantly reduced bacterial growth (p < 0.05). The ZnO + MgO combination demonstrated superior antibacterial effects compared to individual coatings. Nanoparticles remained stable after 24-h agitation in artificial saliva and brushing, maintaining 60%-65% stability.

CONCLUSION

The aligners coated with ZnO nanoparticles exhibited the least colour change and the highest translucency compared to those coated with MgO nanoparticles and the ZnO + MgO combination. The highest antibacterial properties were observed in the aligners coated with a combination of ZnO and MgO nanoparticles.

A study on the compressive strength of three-dimensional direct printing aligner material for specific designing of clear aligners

BACKGROUND

The demand for orthodontic treatment using clear aligners has been gradually increasing because of their superior esthetics compared with conventional fixed orthodontic therapy. This study aimed to evaluate and compare the compressive strength of three-dimensional direct printing aligners (3DPA) with that of conventional thermo-forming aligners (TFA) to determine their clinical applicability. In the experimental group, the 3DPA material TC-85 (TC-85 full) was used to create angular protrusions called rectangular pressure areas (RPA). A protrusion akin to the power ridge typically employed in conventional TFAs was created using glycol-modified polyethylene terephthalate (PETG; Control 1). RPA was created using the same TC-85 without filling the protrusions (TC-85 blank; Control 2). Compression cycle tests were conducted on an LTM 3 h electrodynamic testing machine (Zwick Roell, Germany), with 500 cycles and compression depths of 100, 300, 500, and 700 µm. Twenty specimens were tested for PETG, 17 for the TC-85 blank, and 19 for the TC-85 full.

RESULTS

Changes in the compressive force were assessed based on the material and thickness. The results indicated significantly higher and broader ranges of compressive strength for specimens fabricated with the 3DPA material TC-85 compared with those fabricated using PETG. Among the TC-85 specimens, TC-85 full demonstrated the highest statistically significant compressive strength .

CONCLUSIONS

3DPA technology enables precise modifications in the shape and inner thickness at specific dental sites, including the creation of ridges in targeted areas, of aligners. These alterations enhance the biomechanical capability of aligners to exert selective forces necessary for desired tooth movement while reducing the number of attachments, thereby demonstrating the clinical potential of 3D-printed aligners in orthodontic treatment.

Comparison of physical, mechanical, and optical properties between thermoplastic materials and 3-dimensional printing resins for orthodontic clear retainers

INTRODUCTION

This study investigated the physical, mechanical, and optical properties of 3-dimensional (3D) printing resins compared with thermoplastic materials to evaluate their suitability for the fabrication of orthodontic clear retainers.

METHODS

Samples were prepared from thermoplastic sheets (Duran [Scheu-Dental GmbH, Iserlohn, Germany] and Zendura [Bay Materials LLC, Fremont, Calif]) and biocompatible 3D-printing resins (Dental LT Clear V2 [Formlabs Inc, Somerville, Mass] and OrthoFlex [Nextdent BV, Soesterberg, The Netherlands]) according to the manufacturer's instructions. The materials were characterized by Fourier transform infrared spectroscopy, differential scanning calorimetry, and water sorption tests. Mechanical properties were assessed by tensile tests and hardness under 3 different conditions: dry, wet (24-hour water immersion), and aged (thermocyled for 10,000 cycles). Surface characteristics were qualitatively and quantitatively evaluated by scanning electron microscopy and 3D confocal imaging, respectively. Optical properties were assessed by ultraviolet-visible spectroscopy and color stability tests by immersion into various staining solutions.

RESULTS

The mechanical properties of the 3D-printing resins were more markedly altered in different testing conditions (dry, wet, and aged) than in thermoplastic materials. The surface roughness, transparency, and color stability of 3D-printing resins are significantly inferior, especially NextDent OrthoFlex.

CONCLUSIONS

The evaluated 3D-printing resins are more brittle and less ductile compared with the thermoplastic materials. The 3D-printing resins also do not meet the clinical thresholds of surface roughness and optical properties for the fabrication of orthodontic clear retainers. Further postprocessing of the 3D-printing resins may be required to improve these properties.

Directly printed aligner therapy: A 12-month evaluation of application and effectiveness

INTRODUCTION

Directly printed aligners (DPAs) are gaining in popularity, potentially streamlining manufacturing, decreasing environmental waste, and offering enhanced adaptation and tailoring. This transition has been facilitated by advances in materials, software, and production. Although DPAs may have enhanced versatility and application in the management of more complex malocclusions, there is little research evaluating their effectiveness.

METHODS

A total of 54 patients undergoing treatment with DPAs were evaluated for occlusal improvement, overall treatment duration, and adverse effects. Regression models were fit to evaluate the association between the need for refinement, final peer assessment rating (PAR) score, and independent variables, including the total number of aligners and treatment indications.

RESULTS

The mean number of aligners in the initial plan was 7.1 ± 2.9 and 5.1 ± 4.3 in maxillary and mandibular arches. Refinement was required in 40.8% (n = 20). The pretreatment PAR score of 17.01 ± 7.93 showed a significant improvement (86.6%), with a final PAR score of 2.25 ± 1.15. Minor complications were noted in 3 participants. The need for refinement was unrelated to the total number of aligners (odds ratio, 1.05; 95% confidence interval, 0.94-1.18; P = 0.36). There was weak evidence of an association between the final PAR score and the total number of aligners (odds ratio, -0.03; 95% confidence interval, -0.07 to 0.003, P = 0.07).

CONCLUSIONS

On the basis of this preliminary retrospective evaluation, DPAs may be used to manage mild-moderate malocclusion, producing a significant reduction in PAR score. Nevertheless, additional prospective research is required to confirm these findings and compare the relative merits of DPAs to alternatives.

Effect of post-printing curing time on cytotoxicity of direct printed aligners: A pilot study

INTRODUCTION

The aim of this in vitro study was to examine the potential impact of different curing times of 3D-printed orthodontic aligners on their cytotoxicity.

METHOD

Some 60 samples of aligner material were directly 3D printed using Tera Harz TC-85 DAC resin and randomly allocated to three different curing time groups (14, 24 and 50 min). Zendura FLX samples were used as control. The samples were incubated in saliva for 14 days, and then the supernatant was collected. Human gingival fibroblasts (HGF-1)-CRL2014 were used to evaluate potential cytotoxicity. Furthermore, HGF-1 cells were plated on the samples as well as on a glass control sample. After 72 h of growth, their viability was tested.

RESULTS

Compared with the glass, only the 50-min curing time markedly reduced fibroblast cell growth. Additionally, a negative linear trend was observed between curing time and fibroblast growth. In comparison with the aligner control group, all samples, including the aligner control samples, exhibited a significant reduction in the viability of human fibroblasts when exposed to saliva.

CONCLUSIONS

3D directly printed aligners showed a cytotoxic effect similar to that of thermoformed conventional aligners in terms of fibroblasts growth. A linear trend was found between curing time and cells growth, indicating that directly printed aligners could exhibit higher cytotoxicity if exposed to a longer curing time. This dependence on curing time underscores the importance of following a strict manufacturing process.

Effects of aging on the tensile strength and surface condition of orthodontic aligners: a comparative study of five models

BACKGROUND/OBJECTIVE

The objective of this study is to determine the effect of aging on tensile strength and surface condition of orthodontic aligners on days 0, 1, 5, 7, 10, and 14.

MATERIALS/METHODS

The total sample of 80 aligners included five brands (Accusmile®, Angel®, GRAPHY®, Invisalign® and Suresmile®) were placed in a thermocycler to imitate the temperature variations of the oral cavity and accelerate aging for 50, 250, 350, 500, and 700 cycles. The mechanical tensile properties (Young's modulus E, yield strength YS, maximum elastic stress MES, Ultimate Tensile Strength UTS, and maximum stress MS) were measured by Universal Testing Machine at a rate of 5 mm of deformation per minute for 4 minutes. Microscopic observations were made under a voltage of 10 kV at magnifications times 50, 250, 500, 1000, and 2500 after cleaning with ethanol and ultrasound then metallization with gold.

RESULTS

YS and MES of Angel® aligners are statistically reduced after five days of aging (P = .003). Aligners from the most rigid to the most flexible are (decreasing E): Accusmile® > GRAPHY® > Suresmile® > Invisalign® > Angel®. Surface conditions also deteriorated with aging (appearance of scratches, porosity, cracks, etc.). GRAPHY® aligners are more heterogeneous and weaker than others.

LIMITS

In vitro study.

CONCLUSION

Mechanical properties of Accusmile®, GRAPHY®, Invisalign®, and Suresmile® were not affected by aging. YS and MES were reduced from day 5 for Angel® aligners. Surface conditions are also altered by aging.

Evaluation of different designs of 3D printed clear aligners on mandibular premolar extrusion using force/moment measurement devices and digital image correlation method

Objective

This study aimed to investigate the effect of three-dimensional (3D) printed clear aligners (CA) with different designs on the extrusion of mandibular premolars using a force/moment measurement system and digital image correlation (DIC).

Methods

The forces and moments applied to the mandibular canines, first and second premolars were measured using a multi-axis force/moment transducer when an extrusion of 0.5 mm was planned, assuming the mandibular first premolars were intruded by 1 mm. In addition, displacement and strain changes in the CA were analyzed using the DIC method. CA designs were categorized based on the presence of first premolar attachment and subdivided into equigingival margins, 1-mm extended margins, equi-margins with 1-mm thickness and height, and equi-margins with 1-mm reduced buccolingual width. The CA was printed directly at a thickness of 0.5 mm, and the experiments were conducted at 37°C.

Results

The results showed that attachment played an important role in the extrusion of first premolars in both the force/moment measurement system and the DIC method. Intrusion was observed without attachment, even though extrusion was planned. CA designs apply greater force to the cervical region by extending the margin or reducing the buccolingual width, thereby improving extrusion efficiency.

Conclusions

Force and moment changes in direct 3D printed CA are complex and difficult to predict; however, modifying aligner designs, such as extending the margin or reducing buccolingual width, and using appropriate attachments could minimize unwanted tooth movement, optimize planned treatment, and increase treatment predictability.

The new additive era of orthodontics: 3D-printed aligners and shape memory polymers-the latest trend-and their environmental implications

The era of printed aligners has just began in the orthodontic field. Orthodontists have become more interested in 3D-printed in-office aligners. Treatment due to this technology can become faster and more efficient. Advantages highlighted by newly introduced materials for manufacturing processes of 3D aligners present the possibility of overcoming limitations faced by thermoformed aligners, making them a potential replacement of thermoformed aligner. Advances in aligner material, especially shape memory polymers, have the potential to bring about radical transformations in the clinical applications of clear aligner therapy. Safety and cytotoxicity of printable resins along with its mechanical properties must be scientifically studied extensively before it is cleared for clinical use. In addition, with the increased use of aligners, awareness of the environmental burden of plastic waste should be emphasized. Attention should be directed into the development of recyclable materials for aligners along with establishing clear recycling guidelines and patient education programs on proper recycling methods. With the introduction of Graphy's clear biocompatible photocurable resin, which is equipped with a shape-memory function and is printed in an environmental friendly way by reducing carbon emissions. Direct 3D printing represents the future of clear aligner therapy, and more studies to test these new technologies and materials are required.

Seeking orderness out of the orderless movements: an up-to-date review of the biomechanics in clear aligners

INTRODUCTION

Although with increasing popularity due to aesthetic appeal and comfort, clear aligners (CAs) are facing challenges in efficacy and predictability. Advancement in the underlying biomechanical field is crucial to addressing these challenges. This paper endeavors to provide a comprehensive framework for understanding the biomechanics of CA and enlightening biomechanics-based improvements on treatment strategies.

METHODS

A thorough review of the English-language literature accessible through PubMed and Google Scholar, without any publication year restrictions, was undertaken to unravel the biomechanical aspects of CA.

RESULTS

This review presented an up-to-date understanding of aligner biomechanics arranged by the framework of the material-dependent mechanical characteristics of CA, the geometric characteristics-dependent force transmission of the CA system, methods for studying the biomechanics of CA, and the biomechanical analyses for different types of tooth movement.

CONCLUSIONS

Biomechanics should be the fundamental concern for concepts, methods and adjuncts attempting to enhance the accuracy and predictability of tooth movement induced by CA. Improvement on material properties and alteration of geometric design of CA are two main approaches to develop biomechanically optimized force system. Exploration of real-world force sensing and monitoring system would make substantial progresses in aligner biomechanics.

Three-Dimensionally-Printed Polymer and Composite Materials for Dental Applications with Focus on Orthodontics

Three-dimensional printing has transformed dentistry by enabling the production of customized dental restorations, aligners, surgical guides, and implants. A variety of polymers and composites are used, each with distinct properties. This review explores materials used in 3D printing for dental applications, focusing on trends identified through a literature search in PubMed, Scopus, and the Web of Science. The most studied areas include 3D-printed crowns, bridges, removable prostheses, surgical guides, and aligners. The development of new materials is still ongoing and also holds great promise in terms of environmentally friendly technologies. Modern manufacturing technologies have a promising future in all areas of dentistry: prosthetics, periodontology, dental and oral surgery, implantology, orthodontics, and regenerative dentistry. However, further studies are needed to safely introduce the latest materials, such as nanodiamond-reinforced PMMA, PLA reinforced with nanohydroxyapatite or magnesium, PLGA composites with tricalcium phosphate and magnesium, and PEEK reinforced with hydroxyapatite or titanium into clinical practice.

Polymerization kinetics of 3D-printed orthodontic aligners under different UV post-curing conditions

BACKGROUND

The purpose of the study was to measure the degree of conversion (DC) of direct-printed aligners (DPA) that were post-cured under ambient and nitrogen atmosphere at specific time intervals and investigate the kinetics of polymerization reaction of this material.

METHODS

A total of 48 aligners were produced in 4 printing series by a 3D printer with TC-85DAC resin (Graphy Inc). From each series of printing, 12 aligners were included. The aligners were divided into two groups according to their post-curing conditions. One group was post-cured under ambient air with the presence of oxygen and the other under a nitrogen atmosphere, both using the same UV post-curing unit recommended by the company. The aligners were post-cured at six different time intervals: 1, 2, 3, 5, 10, and 20 min. Each time interval included 8 aligners, with 2 aligners from each series. The DC of the cured aligners was measured by means of attenuated total reflection Fourier-transform infrared spectroscopy (ATR-FTIR) through acquisition of the respective spectra for each UV-curing condition. Statistical analysis was performed to compare the results and differences within each atmosphere post-curing protocol, as well as between the different selected atmosphere conditions. Statistical significance level was set at p-value ≤ 0.05.

RESULTS

Pairwise analysis between post-curing protocols showed statistically significant differences only at the first minute of polymerization. Post-curing with nitrogen did not yield statistically significant results across different time intervals. Post-curing in ambient air showed some significant differences on the 1st and 2nd minute of the post-curing process.

CONCLUSIONS

Almost complete double bond conversion was observed. Significant differences were observed only during the first minute of polymerization under the nitrogen atmosphere.

Enhancing biofilm resistance and preserving optical translucency of 3D printed clear aligners through carboxybetaine-copolymer surface treatment

OBJECTIVES

This study aimed to use a carboxybetaine methacrylate (CBMA) copolymer solution to surface treat 3D printed clear aligners at different fabrication stages, to impart antifouling properties, and assess the surface treatment at various fabrication stages' impact on physico-mechanical characteristics.

METHODS

Surface treatments using a blend of 2-hydroxyethyl methacrylate (HEMA) and CBMA, termed CCS, were performed at various stages of 3D printed clear aligner fabrication. Experimental groups, CB1, CB2, and CB3, were determined by the stage of surface treatment during post-processing. CB1, CB2, and CB3 received treatment before post-curing, after post-curing, and after post-processing, respectively. Untreated samples served as controls. Physical and mechanical properties were assessed through tensile testing, Fourier-transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), and UV-Vis spectroscopy. The surface was further characterized through scanning electron microscopy and contact angle measurements. The cytotoxicity was assessed with 7-day elution and agar diffusion assays. Lastly, bacterial biofilm resistance was evaluated using confocal laser scanning microscopy. Crystal violet assay was performed using Streptococcus mutans.

RESULTS

Surface treatment during CB1 stage exerted the most significantly unfavorable influence on properties of the 3D printed aligner resin. CB2 samples showed the maximum preservation of translucency even after 7-day aging. CB2 and CB3 phases showed enhanced hydrophilicity of sample surfaces with reduced adhesion of multispecies biofilm and S. mutans.

SIGNIFICANCE

Application of CCS surface treatment immediately after post-curing (CB2) can enhance the biofilm resistance of 3D printed clear aligners while maintaining high fidelity to optical translucency and constituent mechanical properties.

Evaluation of thickness of 3D printed versus thermoformed aligners: A prospective in vivo ageing experiment

BACKGROUND

To compare and investigate the effects of intraoral ageing on the thickness of one group of directly printed and two groups of thermoformed aligners on the labial surface of maxillary central incisors.

MATERIALS AND METHODS

Six groups (12 samples per group) were included in this prospective in vivo experiment. Groups DP-Clin, INV-Clin and CA-Clin consisted of directly printed (Tera Harz TC-85 DAC resin), thermoformed (Invisalign, PU based polymer) and in house thermoformed (CA-Pro, PET-G based polymer) aligners, retrieved after 1 week of intraoral service. Groups DP-Ctr, INV-Ctr and CA-Ctr included unused aligners samples. Thickness measurements were conducted using confocal laser scanning microscopy (CLSM). Data that underwent log-10 transformation was analysed by multiple linear regression analysis (p < .05).

RESULTS

Statistically significant differences were found between the materials in both Clin and Ctr categories (p < .001). Group DP had the highest thickness among the groups and the least thickness was observed in the CA group (p < .001). However, intraoral ageing did not significantly affect the aligner thickness of any groups.

CONCLUSIONS

Both thermoforming and direct printing of clear aligners led to thickness deviations in terms of increase for printed aligners and decrease for thermoformed aligners. Intraoral ageing did not affect the aligner thickness in any of the groups.

Accuracy of soy-based resins for dental 3D printing

OBJECTIVES

To verify the accuracy of soy-based resins for dental three-dimensional (3D) printing.

MATERIALS AND METHODS

After conducting a power analysis, models of 10 consecutively treated patients were produced from four different resins using a dental 3D printer. Two of these resins were soy based and therefore biodegradable. These 20 models were measured manually with a caliper as well as digitally by software and compared based on measurement parameters in all three spatial axes.

RESULTS

No statistically significant differences were found between the four different resins or between the manual and digital measurements.

CONCLUSIONS

Soy-based resin seems to be a suitable material for orthodontic 3D printing and is a more environmentally friendly alternative to conventional dental resins. Digital model analysis seems to produce comparable results to manual measurement.

Prospects for 3D-printing of clear aligners—a narrative review

Clear aligner therapy is a rapidly developing orthodontic treatment. 3D-printing technology, which enables the creation of complex geometric structures with high precision, has been used in dentistry. This article aims to summarize the various aspects of 3D-printing clear aligners and give an outlook on their future development. The traditional thermoforming technology is introduced and the principle and application of 3D-printed clear aligners and materials are introduced, as well as the application prospects of 3D-printed clear aligners. According to PRISMA statement, the relevant literature of 3D-printing clear aligner was searched in PubMed, Web of Science, Embase and other databases. We searched the related words in the MESH database and then carried out advanced searches. We read systematic review and conference papers to find the articles related to the subject and manually added and excluded articles by reading the title and abstract. The production of clear aligners combines computer-aided 3D analysis, personalized design and digital molding technology. The thickness and edges of the 3D-printed clear aligner can be digitally controlled, which allows appliance more efficiently fitted. Presently, the array of clear resins suitable for 3D-printing include photo polymeric clear methacrylate-based resin (Dental LT) (Form Labs, Somerville, Mass), aliphatic vinyl ester-polyurethane polymer (Tera Harz TC-85) (Graphy, Seoul, South Korea). They all have good biocompatibility. But no such material is currently approved on the market. Developing biocompatible resins and further improving the material’s mechanical properties will be critical for the combination of 3D-printing and clear aligners. However, the literature on 3D-printed clear aligners is limited and lacks clinical application. Further in vivo and in vitro tests, as well as additional exploration in conjunction with corresponding cytological tests, are required for the research on available materials and machinery for 3D-printing clear aligners.

Evaluation of the effects of temperature and centrifugation time on elimination of uncured resin from 3D-printed dental aligners

The study investigated the effects of temperature and centrifugation time on the efficacy of removing uncured resin from 3D-printed clear aligners. Using a photo-polymerizable polyurethane resin (Tera Harz TC-85, Graphy Inc., Seoul, Korea), aligners were printed and subjected to cleaning processes using isopropyl alcohol (IPA) or centrifugation (g-force 27.95g) at room temperature (RT, 23 °C) and high temperature (HT, 55 °C) for 2, 4, and 6 min. The control group received no treatment (NT). Cleaning efficiency was assessed through rheological analysis, weight measurement, transparency evaluation, SEM imaging, 3D geometry evaluation, stress relaxation, and cell viability tests. Results showed increased temperature and longer centrifugation times significantly reduced aligner viscosity, weight (P < 0.05), and transmittance. IPA-cleaned aligners exhibited significantly lower transparency and rougher surfaces in SEM images. All groups met ISO biocompatibility standards in cytotoxicity tests. The NT group had higher root mean square (RMS) values, indicating greater deviation from the original design. Stress relaxation tests revealed over 95% recovery in all groups after 60 min. The findings suggest that a 2-min HT centrifugation process effectively removes uncured resin without significantly impacting the aligners' physical and optical properties, making it a clinically viable option.

Class II Correction and Crowding Treatment Using In-House Direct Printed Clear Aligners: A Literature Review and Case Report

Clear aligner therapy has significantly improved orthodontic treatment by offering patients a more aesthetically pleasing option compared to traditional braces. This literature review and case report specifically focus on the effectiveness of directly printed clear aligners in treating Class II malocclusions and crowding. Class II malocclusions are characterized by excessive overjet, which often results from skeletal or dental discrepancies between the upper and lower jaws. Crowding refers to the lack of space for teeth within the dental arch, leading to misalignment and potential functional issues. The review and case report highlight the increasing importance of directly printed clear aligners in modern orthodontics and provide clinicians with a valuable tool to effectively address complex malocclusions and crowding while also meeting patient needs for discretion and comfort. Further research is necessary to validate the long-term stability and outcomes of directly printed clear aligner therapy in various orthodontic cases. A detailed case report demonstrates the successful treatment of a patient with Class II malocclusion and mild crowding using directly printed clear aligners. Treatment outcomes include improvements in dental alignment, occlusion, and facial aesthetics, showcasing the effectiveness of this innovative approach.

Effect of the Height of a 3D-Printed Model on the Force Transmission and Thickness of Thermoformed Orthodontic Aligners

This research aims to investigate the influence of model height employed in the deep drawing of orthodontic aligner sheets on force transmission and aligner thickness. Forty aligner sheets (Zendura FLX) were thermoformed over four models of varying heights (15, 20, 25, and 30 mm). Normal contact force generated on the facial surface of the upper right central incisor (Tooth 11) was measured using pressure-sensitive films. Aligner thickness around Tooth 11 was measured at five points. A digital caliper and a micro-computed tomography (µ-CT) were employed for thickness measurements. The normal contact force exhibited an uneven distribution across the facial surface of Tooth 11. Model 15 displayed the highest force (88.9 ± 23.2 N), while Model 30 exhibited the lowest (45.7 ± 15.8 N). The force distribution was more favorable for bodily movement with Model 15. Thickness measurements revealed substantial thinning of the aligner after thermoforming. This thinning was most pronounced at the incisal edge (50% of the original thickness) and least at the gingivo-facial part (85%). Additionally, there was a progressive reduction in aligner thickness with increasing model height, which was most significant on the facial tooth surfaces. We conclude that the thermoplastic aligner sheets undergo substantial thinning during the thermoforming process, which becomes more pronounced as the height of the model increases. As a result, there is a decrease in both overall and localized force transmission, which could lead to increased tipping by the aligner and a diminished ability to achieve bodily movement.

Thickness Variations of Thermoformed and 3D-Printed Clear Aligners

Objective

To assess thickness variations of thermoformed and 3D-printed clear aligners.

Materials and Methods

Six different thermoplastic materials with different initial thicknesses were used for aligner thermoforming using Biostar® device (Biostar®, SCHEU-DENTAL GmbH, Iserlohn, Germany). Also, two different dental resins were used to create the printed aligners in three digitally designed thicknesses using IZZI Direct printer (3Dtech, Zagreb, Croatia). The aligners were measured using an electronic micrometer (ELECTRONIC UNIVERSAL MICROMETER, Schut Geometrical Metrology, Groningen, The Netherlands, accuracy: 0.001 mm) on a total of 20 points per aligner. Statistical analysis was performed using the JASP program (JASP, University of Amsterdam, Amsterdam, The Netherlands).

Results

The difference between the thermoformed and printed groups was statistically significant. Significant differences between different thermoformed materials and between 3D-printed materials were found. The thickness of thermoformed aligners deviated more in the upper jaw, whereas the thickness of printed aligners deviated more in the lower jaw. Both differences were statistically significant. The greatest average deviation from the initial thickness was found in Duran 0.75; Erkodur 0.6; Erkoloc-Pro 1.0; IZZI 0.5; NextDent 0.6 and NextDent A 0.6. NextDent group had the lowest deviations for all teeth of both jaws, except for upper and lower first molar where NextDent A group was more accurate.

Conclusions

Thermoformed aligners showed decreased values, while printed ones showed mostly increased values compared to the original material thickness. The highest mean deviation belonged to IZZI group, and the NextDent group had the lowest mean deviation. The thickness of both aligners was thinner at the edges compared to the thickness at cusps and fissures.

Accuracy of orthodontic movements with 3D printed aligners: A prospective observational pilot study

Objective

Owing to the availability of 3D software, scanners, and printers, clinicians are encouraged to produce in-office aligners. Recently, a new directprinting resin (Tera Harz TC-85DAC) has been introduced. Studies on its mechanical characteristics and biological effects have been published; however, evidence on its efficacy in orthodontic treatment remains scarce. This pilot study aimed to investigate the accuracy of teeth movement achieved with directprinted aligners.

Methods

Seventeen patients (eight males and nine females) with a mean age of 27.67 ± 8.95 years, presenting with dental rotations < 30° and spaces/crowding < 5 mm, were recruited for this study. The teeth movement was planned starting from a T0 digital dental cast. The 3D direct-printed aligners were produced using Tera Harz TC-85DAC resin. Once the orthodontic treatment was completed, a final digital cast was obtained (T1). The planned teeth positions were then superimposed onto the T0 and T1 digital models. The differences between the programmed movements and the achieved overall torque, tip, rotation, and transverse dimensions were assessed using the paired t test or Wilcoxon's signed rank test.

Results

The overall accuracies for torque, tip, and rotation were 67.6%, 64.2%, and 72.0%, respectively. The accuracy of the change in transverse diameter was 99.6%.

Conclusions

Within the limits of the present pilot study (difficulties with abnormally shaped teeth and use of attachments), it can be concluded that 3D printed aligners can be successfully printed in-house and utilized for mildly crowded cases, with a comparable accuracy of tooth movement to that of other aligners.

Numerical biomechanical finite element analysis of different trimming line designs of orthodontic aligners: An in silico study

BACKGROUND

A finite element model was used to investigate the effect of different designs and thicknesses of orthodontic aligner margins on their biomechanical behavior.

METHODS

A three-dimensional data set of an upper jaw was imported into the 3-matic software. The upper right central incisor tooth (Tooth 11) was separated from the remaining model, and its periodontal ligament and surrounding bone were designed. Aligners were designed with four different trimming lines (scalloped, straight, scalloped extended, straight extended), each with four different thicknesses (0.3, 0.4, 0.5, and 0.6 mm). The models were imported into a finite element package (Marc/Mentat). A linear elastic constitutive material model was applied. A facial 0.2 mm bodily malalignment of tooth 11 was simulated.

RESULTS

The maximum resultant force was in the range of 1.0 N to 2.2 N. The straight trimming designs deliver higher resultant forces compared with scalloped trimming designs. Increasing the aligner thickness and/or extending the aligner edge beyond the gingival line leads to an increase in the resultant force. All designs showed an uneven distribution of the normal contact forces over the tooth surface with a predominant concentration toward the cervical third and distal third, particularly with the extended trimming designs. All designs showed uncontrolled tipping of the tooth.

CONCLUSIONS

Based on the current model outcomes, the use of a straight extended trimming line design for aligners is favored because of its positive impact on force distribution and, consequently, the control of tooth movement.

CLINICAL RELEVANCE

These findings provide aligner companies and orthodontists a valuable biomechanical evidence and guidance to enhance control over tooth movement and therefore optimize treatment outcomes. This can be achieved by trimming the edges of aligners with a straight extended design and selecting the appropriate aligner thickness.

Direct 3D printing aligners - past, present and future possibilities

The aim of this paper is to introduce the general dentist to recent advances in 3D printing technology used in orthodontics. 3D printing is a highly evolving area of dentistry with continual developments. New advances now allow the in-house delivery of printed aligners. Advocates of this new technology suggest the benefits of more prescriptive and controlled tooth movement in comparison to conventional thermoformed appliances. However, there is currently limited evidence on the efficiency of this material and more research needs to be carried out to validate this new technology.

Physiochemical and mechanical characterisation of orthodontic 3D printed aligner material made of shape memory polymers (4D aligner material)

OBJECTIVES

To conduct a physiochemical and mechanical material analysis on 3D printed shape-memory aligners in comparison to thermoformed aligners.

MATERIALS AND METHODS

Four materials were examined, including three thermoformed materials: CA Pro (CP), Zendura A (ZA), Zendura FLX (ZF), and one 3D printed material: Tera Harz (TC-85). Rectangular strips measuring 50 × 10 × 0.5 mm were produced from each material. Five tests were conducted, including differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), shape recovery tests, three-points bending (3 PB), and Vickers surface microhardness (VH).

RESULTS

DSC recorded glass transition temperatures (Tg) at 79.9 °C for CP, 92.2 °C for ZA, 107.1 °C for ZF, and 42.3 °C for TC-85. In DMA analysis at 20-45 °C, a prominent decrease in storage modulus was observed, exclusively for TC-85, as the temperature increased. Notably, within the temperature range of 30-45 °C, TC-85 exhibited substantial shape recovery after 10 min, reaching up to 86.1 %, while thermoformed materials showed minimal recovery (1.5-2.9 %). In 3 PB test (at 30, 37, 45 °C), ZA demonstrated the highest force at 2 mm bending, while TC-85 exhibited the lowest. Regarding VH at room temperature, there was a significant decrease for both ZA and ZF after thermoforming. ZA had the highest hardness, followed by ZF and TC-85, with CP showing the lowest values.

CONCLUSIONS

TC-85 demonstrates exceptional shape memory at oral temperature, improving adaptation, reducing force decay, and enabling, together with its higher flexibility, extensive tooth movement per step. Additionally, it maintains microhardness similar to thermoformed sheets, ensuring the durability and effectiveness of dental aligners.

CLINICAL RELEVANCE

The 3D printed aligner material with shape memory characteristics (4D aligner) has revolutionized the orthodontic aligner field. It showed mechanical properties more suitable for orthodontic treatment than thermoforming materials. Additionally, it offers enhanced control over aligner design and thickness, while optimizing the overall workflow. It also minimizes material wastage, and reduces production expenses.

Advancements in Clear Aligner Fabrication: A Comprehensive Review of Direct-3D Printing Technologies

Clear aligners have revolutionized orthodontic treatment by offering an esthetically driven treatment modality to patients of all ages. Over the past two decades, aligners have been used to treat malocclusions in millions of patients worldwide. The inception of aligner therapy goes back to the 1940s, yet the protocols to fabricate aligners have been continuously evolved. CAD/CAM driven protocol was the latest approach which drastically changed the scalability of aligner fabrication-i.e., aligner mass production manufacturing. 3D printing technology has been adopted in various sectors including dentistry mostly because of the ability to create complex geometric structures at high accuracy while reducing labor and material costs-for the most part. The integration of 3D printing in dentistry has been across, starting in orthodontics and oral surgery and expanding in periodontics, prosthodontics, and oral implantology. Continuous progress in material development has led to improved mechanical properties, biocompatibility, and overall quality of aligners. Consequently, aligners have become less invasive, more cost-effective, and deliver outcomes comparable to existing treatment options. The promise of 3D printed aligners lies in their ability to treat malocclusions effectively while providing esthetic benefits to patients by remaining virtually invisible throughout the treatment process. Herein, this review aims to provide a comprehensive summary of studies regarding direct-3D printing of clear aligners up to the present, outlining all essential properties required in 3D-printed clear aligners and the challenges that need to be addressed. Additionally, the review proposes implementation methods to further enhance the effectiveness of the treatment outcome.

Alterations in the surface roughness and porosity parameters of directly printed and Invisalign aligners after 1 week of intraoral usage: An in vivo prospective investigation

INTRODUCTION

Direct printing of clear aligners could be the next paradigm shift in modern orthodontics and can potentially overcome the limitation of the indirect production method. This study investigated the effects of 1 week of intraoral usage on the surface roughness parameters of directly printed aligners (DPAs) and commercially produced Invisalign aligners compared with their unused control counterparts using confocal laser scanning microscopy.

METHODS

The study consisted of 4 groups with 34 samples per group. Unused control aligners were allocated to the control groups (DP-Ctr and INV-Ctr). Sixty-eight patients undergoing clear aligner therapy were allocated to group DP-Clin (patients in therapy using DPAs made from TC-85 DAC resin) and group INV-Clin (patients provided with Invisalign aligners). After 1 week of intraoral usage, the aligners were retrieved from the patients in groups DP-Clin and INV-Clin. Samples were made from the buccal surface of the maxillary right central incisor of each aligner and underwent surface roughness and porosity measuring using confocal laser scanning microscopy. The arithmetic mean deviation of the profile, root mean square deviation, maximum peak height, maximum valley depth, maximum height difference among the highest peak and deepest valley, void volume, and void count were measured. Descriptive analysis and median (quantile) regression models were used for data analysis of this experiment.

RESULTS

One week of intraoral usage significantly increased the surface roughness and porosity of DPAs. In contrast, a significant reduction in the surface roughness and porosity parameters of Invisalign aligners was recorded after intraoral service.

CONCLUSIONS

This study suggests an increase in the surface roughness and surface porosity of DPAs following 1 week of intraoral usage, which might lead to an increase in bacterial adhesion and biofilm formation in these aligners.

Effects of intraoral aging on mechanical properties of directly printed aligners vs. thermoformed aligners: an in vivo prospective investigation

OBJECTIVE

The objective of this study was to examine the impact of intraoral aging on the mechanical properties of directly printed aligners (DPA) compared to thermoformed aligners (TA).

MATERIALS AND METHODS

This prospective in vivo experiment included three types of aligners: DPAs (group DP) fabricated from Tera Harz TC-85 DAC resin (Graphy, Korea), TA (group INV) made from a polyurethane-based polymer (Align Technology, Inc., CA, USA), and TA (group DUR) made from polyethylene glycol terephthalate based polymer (Scheu-Dental, Germany). Each group was categorized into retrieved (Clin) and unused aligners (Ctr). Thirty patients (10 per group) wore the aligners for 7 days, thereby generating the retrieved samples. Thirty unused aligners were employed as control samples. The following mechanical properties were determined: Martens Hardness (HM), indentation modulus (EIT), elastic index (ηIT), and indentation relaxation (RIT). Intergroup comparisons were conducted using ANOVA/Kruskal-Wallis test. Comparisons between retrieved and control samples were done using Wilcoxon-Mann-Whitney-U/Student's t-test/Welch's test.

RESULTS

Statistically significant differences between the groups were found for both control and used samples (P < .001). Pairwise comparisons also revealed significant differences between the samples. The mechanical properties did not differ significantly between unused and retrieved INV- and DUR-aligners, whereas for DP-aligners significant differences for ηIT and RIT were found following intraoral service (P-values .012 and .002, respectively).

CONCLUSIONS

Group DUR showed generally more favorable mechanical properties compared to DP and INV. The much higher RIT and EIT in DP aligners suggest their higher rigidity and force decay, which could compromise their clinical efficacy.

Influence of Post-Processing on the Degree of Conversion and Mechanical Properties of 3D-Printed Polyurethane Aligners

BACKGROUND

This study explores how different post-processing methods affect the mechanical properties and degree of conversion of 3d-printed polyurethane aligners made from Tera Harz TC-85 resin.

METHODS

Using Fourier-transform infrared (FTIR) spectroscopy, the degree of conversion of liquid resin and post-processed materials was analyzed. This investigation focused on the effects of various post-curing environments (nitrogen vs. air) and rinsing protocols (centrifuge, ethanol, isopropanol, and isopropanol + water). The assessed mechanical properties were flexural modulus and hardness.

RESULTS

The degree of conversion showed no significant variance across different groups, though the polymerization environment influenced the results, accounting for 24.0% of the variance. The flexural modulus varied considerably, depending on both the rinsing protocol and the polymerization environment. The standard protocol (centrifugation followed by nitrogen polymerization) exhibited the highest flexural modulus of 1881.22 MPa. Hardness testing revealed significant differences, with isopropanol treatments showing increased resistance to wear in comparison to the centrifuge and ethanol rinse treatments.

CONCLUSIONS

This study conclusively demonstrates the adverse effects of oxygen on the polymerization process, underscoring the critical need for an oxygen-free environment to optimize material properties. Notably, the ethanol rinse followed by nitrogen polymerization protocol emerged as a viable alternative to the conventional centrifuge plus nitrogen method.

From biomimetics to smart materials and 3D technology: Applications in orthodontic bonding, debonding, and appliance design or fabrication

This review covers aspects of orthodontic materials, appliance fabrication and bonding, crossing scientific fields and presenting recent advances in science and technology. Its purpose is to familiarize the reader with developments on these issues, indicate possible future applications of such pioneering approaches, and report the current status in orthodontics. The first section of this review covers shape-memory polymer wires, several misconceptions arising from the recent introduction of novel three-dimensional (3D)-printed aligners (mistakenly termed shape-memory polymers only because they present a certain degree of rebound capacity, as most non-stiff alloys or polymers do), frictionless surfaces enabling resistance-less sliding, self-healing materials for effective handling of fractured plastic/ceramic brackets, self-cleaning materials to minimize microbial attachment or plaque build-up on orthodontic appliances, elastomers with reduced force relaxation and extended stretching capacity to address the problem of inadequate force application during wire-engagement in the bracket slot, biomimetic (non-etching mediated) adhesive attachment to surfaces based on the model of the gecko and the mussel, and command-debond adhesives as options for an atraumatic debonding. This review's second section deals with the recent and largely unsubstantiated application of 3D-printed alloys and polymers in orthodontics and aspects of planning, material fabrication, and appliance design.

The Use of a CAD/CAM Thermoformed Splints System in Closed Reduction of Condylar Fractures

(1) Background: Mandibular fractures are very common. Common indications of closed treatment for mandibular fractures are non-displaced or minimally displaced simple fractures in adult compliant patients with good dentition, the absence of occlusal disruption, and fractures in growing children. In closed treatment, the mandible is maintained in centric occlusion with a maxillomandibular fixation (MMF) with orthodontic elastics. Many methods of MMF have been described, often using orthodontic appliances. In recent years, CAD-CAM technology has improved many procedures used in maxillofacial surgery and orthodontics. The device we present is manufactured following a digital workflow, and was designed specifically for MMF. (2) Materials: Two patients with mandibular fractures were treated with an MMF method whose procedure comprised scanning of the dental arches, followed by construction of thermoformed splints on which buttons for the elastics and retention holes are made. The splints were fixed on the dental arches with composite resin at the level of the holes, and were kept in place for the period of healing of the fracture, with the intermaxillary elastics hooked to the buttons. (3) Results: The application time of the splints was very quick. The splints remained stable for the necessary time, without causing particular discomfort to the patients. (4) Conclusions: From our experience, this technique has proved to be reliable and reproducible and could represent a valid tool in the closed treatment of mandibular fractures.

Forces and moments generated during extrusion of a maxillary central incisor with clear aligners: an in vitro study

OBJECTIVE

To assess the possibility of extrusion of a maxillary central incisor with the use of buccal and lingual pressure columns in the absence of attachments, and to evaluate the forces and moments experienced by the teeth using both thermoformed and 3D-printed clear aligners.

MATERIALS AND METHODS

A three-axis force and moment sensor (Aidin Robotics, Anyang, South Korea) was used to measure the forces and moments during extrusion of an upper left central incisor (UL1) and any forces experienced by the upper right central incisor (UR1) using thermoformed aligners and 3D-printed aligners. For the thermoformed aligners, the materials used were ATMOS® (American Orthodontics, Sheboygan, WI) and Zendura FLX® (Bay Materials LLC, Fremont, CA). 3D-printed aligners were fabricated using TC-85 clear photocurable resin (Graphy Inc., Seoul, South Korea). For each material type, three conditions were tested: Group 1: No attachment or pressure columns (control); Group 2: Attachment only; and Group 3: Pressure columns only. Each group was planned for 0.5 mm of extrusion on the UL1.

RESULTS

All force readings collected demonstrated statistically significant differences when compared by materials and when compared by groups, with a P value of < 0.001. In the absence of attachment or pressure columns (Group 1), ATMOS® and TC-85 groups exerted extrusive force on the UL1. However, significantly lower forces and moments were exerted by the TC-85 group in comparison to the ATMOS® and Zendura FLX® groups. In the presence of attachment (Group 2), all three ATMOS®, Zendura FLX® and TC-85 groups exerted extrusive force on the UL1, with the TA group showing different directions of faciolingual force, mesiodistal force and faciolingual inclination on the UR1 when compared to the other two thermoformed groups. Whereas in the presence of pressure columns (Group 3), only the TC-85 3D-printed aligner group exerted extrusive force. Thermoformed aligners generated significantly higher mean forces and moments than 3D-printed aligners. Significant levels of unintended forces and moments were present in all groups.

CONCLUSIONS

Force levels generated during extrusion with clear aligners are significantly lower with those 3D-printed using TC-85 than with those thermoformed using ATMOS® or Zendura FLX®. Attachments consistently generated extrusive forces, and may be an effective adjunct in achieving extrusion of incisors. Extrusion may be achieved without the use of attachments by utilizing pressure columns in 3D-printed aligners using TC-85. While different strategies can generate extrusive forces, there are significant unintended forces and moments.

Forces and moments generated by 3D direct printed clear aligners of varying labial and lingual thicknesses during lingual movement of maxillary central incisor: an in vitro study

OBJECTIVE

The objective of this study was to measure the forces and moments exerted by direct printed aligners (DPAs) with varying facial and lingual aligner surface thicknesses, in all three planes of space, during lingual movement of a maxillary central incisor.

MATERIALS AND METHODS

An in vitro experimental setup was used to quantify forces and moments experienced by a programmed tooth to be moved and by adjacent anchor teeth, during lingual movement of a maxillary central incisor. DPAs were directly 3D-printed with Tera Harz TC-85 (Graphy Inc., Seoul, South Korea) clear photocurable resin in 100-µm layers. Three multi-axis sensors were used to measure the moments and forces generated by 0.50 mm thick DPAs modified with labial and lingual surface thicknesses of 1.00 mm in selective locations. The sensors were connected to three maxillary incisors (the upper left central, the upper right central, and the upper left lateral incisors) during 0.50 mm of programmed lingual bodily movement of the upper left central incisor. Moment-to-force ratios were calculated for all three incisors. Aligners were benchtop tested in a temperature-controlled chamber at intra-oral temperature to simulate intra-oral conditions.

RESULTS

The results showed that increased facial thickness of DPAs slightly reduced force levels on the upper left central incisor compared to DPAs of uniform thickness of 0.50 mm. Additionally, increasing the lingual thickness of adjacent teeth reduced force and moment side effects on the adjacent teeth. DPAs can produce moment-to-force ratios indicative of controlled tipping.

CONCLUSIONS

Targeted increases in thickness of direct 3D-printed aligners change the magnitude of forces and moments generated, albeit in complex patterns that are difficult to predict. The ability to vary labiolingual thicknesses of DPAs is promising to optimize the prescribed orthodontic movements while minimizing unwanted tooth movements, thereby increasing the predictability of tooth movements.

Comparison of translucency, thickness, and gap width of thermoformed and 3D-printed clear aligners using micro-CT and spectrophotometer

The present study compared the thickness and gap width of thermoformed and 3D-printed clear aligners (CAs) using micro-computed tomography (micro-CT) and evaluated their translucency using spectrophotometer. Four groups of CAs were tested: thermoformed with polyethylene terephthalate glycol (TS) or copolyester-elastomer combination (TM), and 3D-printed TC-85 cleaned with alcohol (PA) or with centrifuge (PC). CIELab coordinates were measured (n = 10) to evaluate translucency. CAs (n = 10) were fitted onto respective models and micro-CT was performed to evaluate the thickness and gap width. Thickness and gap width were measured for different tooth type and location in sagittal sections on all sides. The PC group showed significantly higher translucency than the PA group, which was similar to the TS and TM groups (p < 0.01). After the manufacturing process, thickness reduction was observed in the thermoformed groups, whereas thickness increase was observed in the 3D printed-groups. The TM group showed the least gap width amongst the groups (p < 0.01). Thermoformed and 3D-printed CAs had significantly varied thicknesses and regions of best fit depending on the tooth type and location. Differences in the translucency and thickness of the 3D-printed CAs were observed depending on the cleaning methods.

Comparison of mechanical properties of 3-dimensional printed and thermoformed orthodontic aligners

INTRODUCTION

Orthodontic treatment using clear aligners has experienced exponential growth since its introduction in the late 1990s. Three-dimensional (3D) printing has also grown in popularity among orthodontists, and companies have begun to produce resins to directly print clear aligners. This study aimed to examine the mechanical properties of commercially available thermoformed aligners and direct 3D-printed aligners under laboratory conditions and a simulated oral environment.

METHODS

Samples were prepared (approximately 2.5 × 20 mm) from 2 thermoformed materials, EX30 and LD30 (Align Technology Inc, San Jose, Calif), as well as 2 direct 3D-printing resins, Material X (Envisiontec, Inc; Dearborn, Mich) and OD-Clear TF (3DResyns, Barcelona, Spain). Wet samples were subjected to phosphate-buffered saline at 37°C for 7 days, whereas dry samples were stored at 25°C. Tensile and stress relaxation tests were carried out on an RSA3 Dynamic Mechanical Analyzer (Texas Instruments, Dallas, Tex) and Instron Universal Testing System (Instron, Norwood, Mass) to calculate elastic modulus, ultimate tensile strength, and stress relaxation.

RESULTS

The elastic modulus of dry and wet samples was 103.2 ± 17.3 MPa and 114.4 ± 17.9 MPa (EX30), 61.3 ± 9.18 MPa and 103.5 ± 11.4 MPa (LD30), 431.2 ± 16.0 MPa and 139.9 ± 34.6 MPa (Material X), and 38.4 ± 14.7 MPa and 38.3 ± 8.4 MPa (OD-Clear TF), respectively. The ultimate tensile strength of dry and wet samples was 64.41 ± 7.25 MPa and 61.43 ± 7.41MPa (EX30), 40.04 ± 5.00 MPa and 30.09 ± 1.50 MPa (LD30), 28.11 ± 3.75 MPa and 27.57 ± 4.09 MPa (Material X), and 9.34 ± 1.96 MPa and 8.27 ± 0.93 MPa (OD-Clear TF), respectively. Residual stress of wet samples at 2% strain for 2 hours was 59.99 ± 3.02% (EX30), 52.57 ± 12.28% (LD30), 6.98 ± 2.64% (Material X), and 4.39 ± 0.84% (OD-Clear TF).

CONCLUSIONS

There was a significant difference in elastic modulus, ultimate tensile strength, and stress relaxation among the samples tested. Moisture, specifically a simulated oral environment, appears to have a greater effect on the mechanical properties of direct 3D-printed aligners when compared with thermoformed aligners. This is likely to impact the ability of 3D-printed aligners to generate and maintain adequate force levels for tooth movement.

Advances in orthodontic clear aligner materials

Rapid technological improvements in biomaterials, computer-aided design (CAD) and manufacturing (CAM) have endorsed clear aligner therapy (CAT) as a mainstay of orthodontic treatment, and the materials employed for aligner fabrication play an all-important role in determining the clinical performance of clear aligners. This narrative review has attempted to comprehensively encompass the entire gamut of materials currently used for the fabrication of clear aligners and elucidate their characteristics that are crucial in determining their performance in an oral environment. Historical developments and current protocols in aligner fabrication, features of contemporary bioactive materials, and emerging trends related to CAT are discussed. Advances in aligner material chemistry and engineering possess the potential to bring about radical transformations in the therapeutic applications of CAT; in the absence of which, clear aligners would continue to underperform clinically, due to their inherent biomechanical constraints. Finally, while innovations in aligner materials such as shape memory polymers, direct three-dimensional (3D) printed clear aligners and bioactive materials combined with clear aligner materials are essential to further advance the applications of CAT; increased awareness of environmental responsibilities among aligner manufacturers, aligner prescribing clinicians and aligner users is essential for better alignment of our climate change goals towards a sustainable planet.

Clinically Relevant Properties of 3D Printable Materials for Intraoral Use in Orthodontics: A Critical Review of the Literature

The review aimed at analyzing the evidence available on 3D printable materials and techniques used for the fabrication of orthodontic appliances, focusing on materials properties that are clinically relevant. MEDLINE/PubMed, Scopus, and Cochrane Library databases were searched. Starting from an initial retrieval of 669 citations, 47 articles were finally included in the qualitative review. Several articles presented proof-of-concept clinical cases describing the digital workflow to manufacture a variety of appliances. Clinical studies other than these case reports are not available. The fabrication of aligners is the most investigated application of 3D printing in orthodontics, and, among materials, Dental LT Clear Resin (Formlabs) has been tested in several studies, although Tera Harz TC-85 (Graphy) is currently the only material specifically marketed for direct printing of aligners. Tests of the mechanical properties of aligners materials lacked homogeneity in the protocols, while biocompatibility tests failed to assess the influence of intraoral conditions on eluents release. The aesthetic properties of 3D-printed appliances are largely unexplored. The evidence on 3D-printed metallic appliances is also limited. The scientific evidence on 3D printable orthodontic materials and techniques should be strengthened by defining international standards for laboratory testing and by starting the necessary clinical trials.

Integrated manufacturing of direct 3D-printed clear aligners

The inception of the laboratory work for a removable tooth moving appliance construction by sectioning the teeth from the malocclusion model to align them with wax and achieve minor dental correction has evolved into a state of digital planning and appliance manufacturing for a wide spectrum of malocclusion. The disruptive technology of directly printing clear aligners has drawn the clinician and researcher's interest in the orthodontic fraternity contemporarily. This workflow enables to the development of an in-house aligner system with complete control over desired aligner thickness, extent, and attachments; also technically resource-efficient with greater accuracy by excluding all the intermediate steps involved in the thermoforming method of manufacturing. This promising exploratory subject demands to be well-received with further research-based improvements. This article intends to summarize the digital orthodontic workflow and the literature evidence.

Force profile assessment of direct-printed aligners versus thermoformed aligners and the effects of non-engaged surface patterns

Background

The purpose of the study was to measure the forces delivered by direct-printed aligners (DPA) in the vertical dimension and compare the force profile with traditional thermoformed aligners (TFA) and to investigate the impact of non-engaged surface patterns to the properties of DPA and TFA.

Methods

A force-measuring appliance was fabricated capable of displacing the aligner in 0.10 mm increments and measuring the resultant force. Polyethylene terephthalate glycol (ATMOS 0.030″ American Orthodontics) and TC-85DAC resin (Graphy Inc) were used to create TFA and DPA, respectively. Aligners were temperature-controlled prior to and during testing to simulate the oral environment. The resultant forces from displacements ranging from 0.10 to 0.30 mm were measured.

Results

At intraoral temperatures, DPA demonstrated significantly less force than TFA. TFA demonstrated a substantial statistically significant increase in force with each 0.10 mm increase in vertical displacement. DPA demonstrated a much more consistent force profile across the range of displacements. The effects of surface patterns in both DPA and TFA were generally a decrease in force. Statistical significance of surface patterns was detected for TFA at displacements of 0.30 mm and greater and significant for DPA only at a displacement of 0.10 mm. Surface patterns in both DPA and the TFA did not show any statistical difference when assessing force proprieties.

Conclusions

Forces delivered by aligners in the vertical dimension by DPA are more consistent and of lower magnitude than those of TFA aligners. Surface patterns were not capable of altering the force properties of both DPA and TFA.

Effect of Trimming Line Design and Edge Extension of Orthodontic Aligners on Force Transmission: An in vitro Study

OBJECTIVES

To investigate how the stress distribution and forces transmitted from orthodontic aligners to the tooth surface are affected by the geometry and extension of the trimming line.

MATERIALS AND METHODS

Thirty-six aligners were thermoformed from Zendura FLX sheets (0.75 mm thick) and divided into four groups based on the design of the trimming line: Scalloped, Scalloped extended, Straight and Straight extended. Fuji pressure-sensitive films were used for pressure measurement. The pressurized films were scanned and evaluated. Pressures and forces were measured over the entire facial surface of an upper right central incisor (Tooth 11) and at 7 different locations [cervical, middle, incisal, mesio-incisal, mesio-cervical, disto-cervical, and disto-cervical]. In addition, the thickness of the aligners at these 7 sites was measured with a digital caliper.

RESULTS

The active force ranged from (2.2 - 6.9) N, and the average pressure was (1.6 - 2.7) MPa. The highest values were recorded for the (straight extended) design, while the lowest values were recorded for the scalloped design. The forces and stresses were not uniformly distributed over the surface. When the values in each area were compared separately, significant differences were found between the different designs in the cervical area, with the scalloped design transmitting the lowest cervical forces. Aligner thickness was drastically reduced (60-75% thinning) over the entire tooth surface after thermoforming.

CONCLUSIONS

The straight extended design of aligner's trimming line exhibited more uniform force transfer and stress distribution across the surface than the other designs.

CLINICAL RELEVANCE

The trimming line design could have a significant impact on the clinical outcome of orthodontic aligner treatment.

Performance Evaluation of CNT Reinforcement on Electroless Plating on Solid Free-Form-Fabricated PETG Specimens for Prosthetic Limb Application

The utility of polymers in the present decade is consistently increasing, giving scope to many applications from automobiles to prosthetics. Polymers used for solid free-form fabrication (SFFF), also known as 3D printing, comprise a quick fabrication process adopted by many industries to increase productivity and decrease the run time to cope with the market demands. In this research work, pure polyethylene terephthalate glycol (PETG) and multi-walled carbon nanotube (MWCNT)-PETG with an electroless metal layer coating and without a coating are discussed. The effect of the electroless metal layer coating on the reinforced PETG-MWCNT results in improved mechanical, tribological, and other surface properties. Pure PETG was incorporated with MWCNT nanofillers at 0.3 wt.% and extruded as a filament through a twin screw extruder with a 1.75 mm diameter and printed on ASTM standards. Tensile testing was performed on all four types of un-coated pure PETG, PETG-MWCNT, and metal-layer-coated PETG and PETG-MWCNT with a coating thickness of 26, 32, 54, and 88 μm. Dynamic mechanical analysis (DMA) showed that the coated PETG-MWCNT had the highest storage and loss modulus. The heat deflection temperature was improved to 88 °C for the coated PETG-MWCNT. The wear volume against the sliding distance at a load of 40, 50, and 60 N showed that the coefficient of friction decreased with an increase in the load. The scratch test results revealed the lowest penetration depth and lowest friction coefficient for the coated PETG-MWCNT sample. The water contact angle test showed that a greater coating thickness makes the sample surface more hydrophobic, and the microhardness test indicated that the indentation hardness value for the PETG-MWCNT was 92 HV. The study revealed that the metal-layer-coated PETG-MWCNT had better performance compared to the other specimens due to a good metal layer bonding on the PETG substrate. It was concluded that adding MWCNTs to a metal layer electroless coating improved the surface and mechanical properties of the PETG, and this may be suitable for many applications.

Three-Dimensional-Printed Customized Orthodontic and Pedodontic Appliances: A Critical Review of a New Era for Treatment

Three-dimensional (3D) designing and manufacturing technology is a direct derivative of digital technology. Three-dimensional volume and surface acquisition, CAD software, and 3D manufacturing are major changes included in daily practice in many orthodontic and pedodontic offices. Customized appliances can be designed using dental CAD software or general-purpose CAD software in the office or a laboratory. Materials that can be used are resins, alloys, or zirconia. Methods: The search strategy of this critical review included keywords in combination with MeSH terms in Medline, Scopus, and Cochrane Library up to June 2022 in the English language without any limit to the publication period. Results: According to our search, 12 articles were selected for our study. All the articles were in vitro prospective studies. Conclusions: The results suggested that almost all the known appliances can be designed and printed in a tailor-made fashion in contrast to the traditional one-size-fits-all approach. Customized appliances should be manufactured according to the patient’s needs, and this is justified by the certainty that this approach will be beneficial for the patient’s treatment. There is a need for more research on all direct 3D-printed appliances.

Effectiveness and Efficacy of Thermoformed and 3D Printed Aligners in Correcting Malocclusion (Spacing) and Its Impact on Periodontal Oral Health and Oral Microbiome: A Double-Blinded Parallel Randomized Controlled Multicenter Clinical Trial

Aligners are the common devices used in orthodontics for the correction of malocclusion. Various materials and techniques are employed to fabricate aligners. One of those includes thermoformed and 3D aligners. These aligners can be worn for several days, and their impact on periodontal health is not known. Therefore, the aim of our protocol is to determine the effectiveness of these aligners in correcting malocclusion and their impact on periodontal health and oral microbiome. A double-blinded randomized controlled clinical trial with a total of n = 60 patients will be included with n = 30 in each group (Test: 3D printed aligners and Control: Thermoformed). The evaluation of oral health indices such as basic periodontal examination (BPE), periodontal screening and recording (PSR) that provide the status of periodontal health will be recorded. The oral microbiome assessment will be conducted with polymerase chain reaction (PCR). The primary endpoint will be the correction of malocclusion, and the secondary end point will be the status of periodontal health and oral microbiome. The duration of follow-up for each group will be 7 days for periodontal health and oral microbiome and 6 months for the space closure of 5 mm by 3D and thermoformed aligners.