Dynamic mechanical and thermal properties of clear aligners after thermoforming and aging

Polydimethylsiloxane enabled triple-action water-resistant coating with desirable relaxation rate in clear aligner

Clear aligners undergo rapid stress relaxation in warm, moist oral environments, compromising therapeutic effectiveness and longevity of treatment. To develop an innovative multilayer composite material with improved stability and reduced stress release, we have engineered an innovative coating characterized by the surface aggregation of polydimethylsiloxane (PDMS), which imparts a pronounced hydrophobic effect. In addition, the chemically and physically cross-linked structure of the coating reduces the free volume created by molecular chain rearrangement owing to the presence of water molecules, thereby minimizing water penetration into the coating. Concurrently, the coating's internal structure is enriched with numerous polar functional groups to capture water molecules that penetrate into the inside of the coating. Through combination of these mechanisms, water molecules are effectively sequestered, thereby impeding their penetration into the polyethylene terephthalate glycol (PETG) substrate. The impact of the polydimethylsiloxane content on the triple-action water-resistance mechanisms was thoroughly examined using attenuated total reflection (ATR)-Fourier transform infrared (FTIR), water absorption rate, water swelling rate, and X-ray photoelectron spectroscopy. The low surface energy cross-linked polyurethane coating is applied to the polyethylene terephthalate glycol (PETG) substrate to create a novel composite material with specific mechanical properties and reduced stress relaxation. The composite material remains stable in simulated oral environment with linear swelling rate of 0.58 % upon water absorption. Additionally, the stress release rate of the composite material within 336 h is notably lower (23.64 %) than that of PETG (62.29 %).

Assessment of the Effect of Thermoforming Process and Simulated Aging on the Mechanical Properties of Clear Aligner Material

Background Choosing the optimal aligner material on the market is crucial to ensure constant forces for tooth displacement. Processes like manufacturing and intraoral usage can result in the degradation of certain properties, which can affect the overall efficacy of treatment. Objective The objective of the study is to compare the surface roughness and flexural modulus of two aligner materials following the processes of thermoforming and aging. Materials and methods Two groups of 12 samples each were tested: Group 1 consisted of polyethylene terephthalate glycol (PET-G) and Group 2 of zendura-polyurethane (PU). The groups were tested at three time points: T0 - pre-thermoformed; T1 - after thermoforming; T2 - after thermoforming and aging. The surface roughness and the flexural modulus were evaluated. One-way ANOVA followed by a Bonferroni post hoc test was conducted to compare the changes within each group across the three times. An independent t-test was done to compare the values between the two groups at each time point. The statistical tests were performed using SPSS software version 26 (IBM Corp., Armonk, NY, USA). P-values >0.05 were considered statistically significant. Results There was a significant change in the surface roughness post-aging in Group 2 (p=0.03) and flexural strength within Group 1 (p=0.031) and Group 2 (p=0.06) across the three time points. Comparing the changes within the three time points in Group 1, significant changes were observed between T0-T1 (p=0.045) and T0-T2 (p=0.07). In Group 2, significant changes were observed between T0-T2 (p=0.012). Comparing the flexural strength between the two groups, significant differences were observed at T0 (p=0.012) and T1 (p=0.001). Conclusion The aging process affected the surface roughness in Zendura (PU). The thermoforming and aging process resulted in reduced flexural strength in both Zendura (PU) and Duran groups (PET-G).

The Influence of Thickness on the Mechanical Behaviors of 3D Printing Resins for Orthodontic Retainers

This study aimed to evaluate the mechanical behaviors of thermoformed and 3D-printed retainers with different thicknesses. Thermoformed retainers (Duran) and 3D-printed retainers (Dental LT Clear V2 and NextDent Ortho Flex) were fabricated at thicknesses of 0.5, 0.75, and 1 mm. Five samples of each material were subjected to compression, tensile, and flexural testing with the universal testing machine (Instron Ltd., Buckinghamshire, England). The results revealed that the mechanical behaviors were significantly influenced by thickness in each type of material. The increased thickness tended to increase strength and modulus in all three tests. However, Dental LT Clear V2 and Duran showed that flexural strength and modulus were inversely related to thickness. The compressive test revealed significantly greater compressive resistance in 3D-printed groups, except for the NextDent Ortho Flex at 0.5 mm. The tensile test showed that Dental LT Clear V2 at all thicknesses demonstrated significantly higher tensile strength and modulus, while NextDent Ortho Flex was significantly lowest at any thickness in tensile and flexural properties. In conclusion, the thickness significantly influenced the mechanical behaviors of the 3D-printed retainers. The 0.75 mm thickness of Dental LT Clear V2 could be considered as an alternative to fabricated retainers due to its similar mechanical properties compared with the thermoformed material.

Surface Topography of Thermoplastic Appliance Materials Related to Sorption and Solubility in Artificial Saliva

(1) Background: PETG (polyethylene terephthalate glycol) is a transparent, inexpensive, and versatile thermoplastic biomaterial, and it is increasingly being used for a variety of medical applications in dentistry, orthopedics, tissue engineering, and surgery. It is known to have remarkable properties such as tensile strength, high ductility, and resistance to chemical insults and heat, but it can be affected by various environmental conditions. The aim of the present study was to evaluate the topographical characteristics of four thermoplastic dental appliance materials in relation to water sorption in simulated oral environments (artificial saliva samples with different pH values). (2) Methods: The following four types of PETG clear thermoplastic materials were selected for the present study: Leone (L), Crystal (C), Erkodur (E), and Duran (D). In relation to the desiccation and water-uptake stages, their water sorption (Wsp) and solubility (Wsl) were calculated, and the surface topographies were analyzed on two length scales. The surface roughness was determined using a contact profilometer, and nanoroughness measurements were generated by three-dimensional profiles using an atomic force microscope (AFM). Statistical analyses (one-way ANOVA and unpaired and paired Student t-tests) were performed. (3) Results: After saliva immersion, the weights of all samples increased, and the highest sorption was recorded in a basic environment. Among the materials, the water uptake for the L samples was the highest, and for E, it was the lowest. In relation to water solubility, significant values were registered for both the L and C samples' materials. After immersion and desiccation, a decreasing trend in microroughness was observed. The AFM high-resolution images reflected more irregular surfaces related to saliva immersion. (4) Conclusions: The sorption rates recorded in water-based artificial saliva were higher for basic pH levels, with significant differences between the samples. There were also significant differences related to the behaviors of the materials included in the study. In relation to roughness, on a microscale, the surfaces tended to be smoother after the saliva immersions, and on a nanoscale, they became more irregular.

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.

Color and Chemical Stability of 3D-Printed and Thermoformed Polyurethane-Based Aligners

The significant rise in the use of clear aligners for orthodontic treatment is attributed to their aesthetic appeal, enhancing patient appearance and self-confidence. The aim of this study is to evaluate the aligners' response to common staining agents (coffee, black tea, Coca-Cola, and Red Bull) in color and chemical stability. Polyurethane-based thermoformed and 3D-printed aligners from four brands were exposed to common beverages to assess color change using a VITA Easyshade compact colorimeter after 24 h, 48 h, 72 h, and 7 days, as well as chemical stability using ATR-FTIR spectroscopy. The brand, beverage, and manufacturing method significantly influence color stability. ATR-FTIR analysis revealed compositional differences, with variations in response to beverage exposure affecting the integrity of polymer bonds. Color change analysis showed coffee as the most potent staining agent, particularly affecting Tera Harz TC85 aligners, while ClearCorrect aligners exhibited the least susceptibility. 3D-printed aligners showed a greater color change compared to thermoformed ones. Aligners with a PETG outer layer are more resistant to stains and chemical alterations than those made of polyurethane. Additionally, 3D-printed polyurethane aligners stain more than thermoformed ones. Therefore, PETG-layered aligners are a more reliable choice for maintaining the aesthetic integrity of aligners.

Cigarette smoke and tobacco heating aerosol on the aging of clear aligners

BACKGROUND

The treatments with clear aligners (CA) showed an exponential higher percentage in the last years being almost invisible with major patient acceptability and a resulting improvement in quality of life. CA are composed of thermoplastic polyurethane not inert but subjected to changes due to heating and humidity, chewing forces, and prolonged exposure to enzymes in saliva in the oral cavity and external factors. Cigarette smoke (CS) and the aerosol produced by tobacco products with reduced health risks may be considered among the external factors affecting CA. The purpose of this study was the assessment of optical properties (absorbance and transmittance) and roughness of CA after in vitro aging due to exposition to CS and THS2.2, compared to controls. The secondary objective will be the investigation of CS and THS2.2 effects on resin composite inside aligners used for attachments during treatment with CA.

METHODS

A total number of 60 CA units will be used and equally divided in three different groups (20 in each): CS group exposed to reference cigarettes smoking, THS2.2 group exposed to aerosol from 20 heat-not-burn sticks, and control group, CG to pure air only. The aligners will present ten introflection for the attachments on the anterior part. In accordance with ISO standard 3402, 3R4F cigarettes and THS2.2 tobacco sticks must undergo conditioning for a minimum of 48 hours and a maximum of 21 days at a temperature of 22±1 °C and a relative humidity of 60±3%.

RESULTS

Using spectrophotometry, the optical characteristics (absorbance and transmittance) of each aligner will be evaluated after aging (Jasco UV-vis V630PC, Tokyo, Japan). Each aligner will be cut with a rotating saw from canine to canine prior to the measurements in order to lop off the lingual region and displaying the labial barrier. The absorbance and transmittance measurements will be collected and statistically analyzed with a significance of P<0.05.

CONCLUSIONS

Surface roughness of the aligners and attachments inside them will be assessed by 3D scanning microscopy (Infinite Focus G4h). Color of resin composite will be assessed using the (CIE Lab) Commission Internationale de l'Eclairage L*a*b* color space by means of Olympus CrystalEyef dental spectrophotometer. Clinicians should advise patients to refrain from smoking and drinking coffee or tea while wearing aligners for two reasons: first, the color change is unacceptably noticeable when wearing aligners, and second, the material's chemical composition may be slightly altered, which could affect the intended dental movements.

Effect of carbamide peroxide on biomechanical properties of vacuum-formed retainers: A split-mouth randomized controlled trial

OBJECTIVE

To investigate the effect of tooth whitening on biomechanical properties of vacuum-formed retainers (VFRs).

METHODS

Using a split-mouth, randomised controlled trial design, thirty participants were randomly allocated to receive whitening on either the upper or the lower arch, using 10 % carbamide peroxide for two weeks. Biomechanical properties such as hardness, tensile strength, and surface roughness were assessed two weeks after whitening was completed.

RESULTS

Tensile strength of the whitening arch (mean ± SD: 40.93 ± 3.96 MPa) was significantly lower than that of the control (47.40 ± 5.03 MPa) (difference 6.47 MPa, 95 % CI 4.51 - 8.42, p < 0.001). Hardness and internal roughness of the whitening arch (VHN = 14.63 ± 2.29 N/mm2 and Ra = 1.33 ± 0.35 µm, respectively) were significantly greater than those of the control (12.22 ± 1.86 N/mm2 and 0.96 ± 0.29 µm, respectively) (differences 2.41 N/mm2, 95 % CI 1.56 - 3.25, p < 0.001 and 0.37 µm, 95 % CI 0.23 - 0.51, p < 0.001, respectively). The whitening arch showed greater tooth colour change (ΔE = 6.00 ± 3.32) than the control (ΔE = 2.50 ± 1.70) (difference = 3.50, 95 % CI 2.43 - 4.56, p < 0.001).

CONCLUSIONS

Based on this short-term study, marked tooth colour change was achieved by whitening with VFRs as the whitening trays, but this changed the VFRs' biomechanical properties, including a decrease in tensile strength and an increase in hardness and internal roughness.

CLINICAL SIGNIFICANCE

The application of carbamide peroxide in VFRs may compromise their mechanical properties.

Effect of clear aligner type on maxillary full-arch intrusion: 3D analysis using finite element method

BACKGROUND

Vertical maxillary excess (VME) is one of the most common reasons for seeking orthodontic treatment. Total intrusion with aligners is a promising alternative to surgery in some cases. Considering the elastic deformation of aligners, this study aimed to evaluate the possible desirable and undesirable teeth displacements during full maxillary arch intrusion using clear aligners and temporary anchorage devices (TADs).

METHODS

The maxillary arch and clear aligners were modeled in SolidWorks. Four aligner brands including Leon, Duran, Duran Plus, and Essix Plus were selected based on their material properties. Anterior and posterior intrusion forces of 80 and 300 g were applied from attachments between the canines and first premolars and between the first and second molars, respectively. Vertical and anteroposterior tooth displacements were determined.

RESULTS

The greatest intrusion was recorded at the buccal of the second molar, followed by the first molar. The lowest value was measured at the palatal of the molars with all aligners except Duran, which indicated minimal intrusion in the central incisor. All teeth were mesially displaced at the incisal/occlusal except incisors that moved distally. All apices showed distal movement.

CONCLUSIONS

Total intrusion using clear aligners may be accompanied by other tooth movements, including buccal tipping and mesial-in rotation of the molars, retrusion of incisors, and mesial movement of other teeth.

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.

Effect of printing orientation on mechanical properties of 3D-printed orthodontic aligners

PURPOSE

The purpose of this study was to assess differences in the fundamental mechanical properties of resin-made three-dimensional (3D) printed orthodontic aligners according to the printing orientation.

METHODS

Twenty resin 3D-printed dumbbell-shaped specimens and 20 orthodontic aligners were fabricated and postcured in nitrogen. Half of the specimens and aligners were built in horizontal (H), the other half in vertical (V) directions. The dumbbell-shaped specimens were loaded in a tensile testing machine, while parts of the aligners were embedded in acrylic resin, ground, polished, and then underwent instrumented indentation testing (IIT). Mechanical properties that were assessed included the yield strength (YS), breaking strength (BS), plastic strain (ε), Martens hardness (HM), indentation modulus (EIT), elastic index (ηIT), and indentation relaxation (RIT). Data were analyzed statistically with independent t‑tests or Mann-Whitney tests at α = 5%.

RESULTS

No significant differences were found between specimens or aligners printed either in a horizontal or a vertical direction (P > 0.05 in all instances). Overall, the 3D-printed aligners showed acceptable mechanical propertied in terms of YS (mean 19.2 MPa; standard deviation [SD] 1.7 MPa), BS (mean 19.6 MPa; SD 1.2 MPa), ε (mean 77%; SD 11%), HM (median 89.0 N/mm2; interquartile range [IQR] 84.5-90.0 NN/m2), EIT (median 2670.5 MPa; IQR 2645.0-2726.0 MPa), ηIT (median 27.5%; IQR 25.9-28.1%), and RIT (mean 65.1%; SD 3.5%).

CONCLUSION

Printing direction seemed to have no effect on the mechanical properties of 3D-printed resin aligners, which are promising for orthodontic use.

The effect of enhanced structure in the posterior segment of clear aligners during anterior retraction: a three-dimensional finite element and experimental model analysis

BACKGROUND

Mesial tipping of posterior teeth occurs frequently during space closure with clear aligners (CAs). In this study, we proposed a new modification of CA by localized thickening of the aligner to form the enhanced structure and investigate its biomechanical effect during anterior retraction.

METHODS

Two methods were employed in this study. First, a finite element (FE) model was constructed, which included alveolar bone, the first premolars extracted maxillary dentition, periodontal ligaments (PDL), attachments and aligners. The second method involved an experimental model-a measuring device using multi-axis transducers and vacuum thermoforming aligners. Two groups were formed: (1) The control group used common CAs and (2) the enhanced structure group used partially thickened CAs.

RESULTS

FE model revealed that the enhanced structure improved the biomechanics during anterior retraction. Specifically, the second premolar, which had a smaller PDL area, experienced a smaller protraction force and moment, making it less likely to tip mesially. In the same vein, the molars could resist movement due to their larger PDL area even though they were applied larger forces. The resultant force of the posterior tooth was closer to the center of resistance, reducing the tipping moment. The canine was applied a larger retraction force and moment, resulting in sufficient retraction of anterior teeth. The experimental model demonstrated a similar trend in force variation as the FE model.

CONCLUSIONS

Enhanced structure allowed force distribution more in accordance with optimal principles of biomechanics during the extraction space closure while permitting less mesial tipping and anchorage loss of posterior teeth and better retraction of anterior teeth. Thus, enhanced structure alleviated the roller coaster effect associated with extraction cases and offered a new possibility for anchorage reinforcement in clear aligner therapy.

Effects of Thermoforming on the Mechanical, Optical, Chemical, and Morphological Properties of PET-G: In Vitro Study

The effectiveness of clear aligners in correcting malocclusions is closely linked to the properties of the materials used to make them. The polymers used in the manufacture of clear aligners have well-established properties. However, the process of manufacturing clear aligners, known as thermoforming, involves thermal and mechanical shocks that may alter these properties. The objective of this study was to evaluate the effects of thermoforming on the mechanical, optical, chemical, and morphological properties of sixty PET-G specimens. The study compared the thickness, weight, absorbance, chemical structure, surface roughness, elastic modulus, yield strength, and breaking load of thirty thermoformed specimens with thirty non-thermoformed specimens. The study introduces a new approach by using standardized samples to analyze both chemical and physical properties. The results showed statistically significant differences in thickness (-15%), weight (-11%), and surface roughness (+1233% in roughness average; +1129% in RMS roughness) of the material. Additionally, a correlation was found between reduction in thickness and increase in opalescence. There was no significant change in the functionality of the aligners after thermoforming, as no significant mechanical changes were found. However, the increase in surface roughness may lead to plaque and fluid accumulation and worsen the fit of the aligners.

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.

In vitro analysis of the influence of the thermocycling and the applied force on orthodontic clear aligners

The mechanical properties of polyurethane dental aligners have been studied in an oral environment at 37°C and subjected to thermal cycling between 5°C and 55°C for long periods of time at different mechanical stresses. The aim is to determine the efficacy of the orthodontic aligner at different stress levels, the effect of thermal cycling with therapy time on tooth position correction. Sixty aligners with the same design were studied applying tensions of 0, 3 and 30 N and determining the deformation at different times from 1 to 760 h. Half of these aligners were subjected to stresses submerged in artificial saliva at 37°C and the other half were subjected to thermal cycles between 2°C and 55°C in salivary medium. Deformation was determined using a high-resolution stereo magnifier and ImageJ image analysis software. Water adsorption by the polyurethane was determined at the different test times. The results showed that in the unloaded aligners there is no appreciable deformation, but with thermal cycling there is a light shrinkage of the aligner due to the semi-crystallization process (ordering of polymeric chains) of the polyurethane. When applying loads of 3 and 30 N, creep curves with constant deformation transition zones can be seen. The transition zones decrease as the applied mechanical load increases. In addition, the significant effect of thermal cycling on the reduction of the transition zone of the aligners has been demonstrated. The transition zones are optimal for dental correction as constant stresses are exerted for tooth movement. The effect of thermal cycling shortens the constant deformation zone and reduces tooth alignment time. It was observed that the absorption of water in the aligner is constant after 1 h of immersion and does not exceed 0.4% by weight of absorbed water.

Differential Stability of One-layer and Three-layer Orthodontic Aligner Blends under Thermocycling: Implications for Clinical Durability

Objectives

To optimize the therapeutic usefulness of aligners, it is crucial to understand how their mechanical properties alter with time.

Materials and methods

Specimens from four different brands, including Duran+, CA® Pro, Zendura A, and Zendura FLX, were produced for material testing of thermoplastic orthodontic aligners (TOA) using dimensions measuring 4mm x 10mm. Each brand's 24 samples were split into three groups as follows: G1 being thermoformed, G2 being thermoformed and underwent 500 thermocycles (simulating 7 days), and G3 being thermoformed and underwent 1000 thermocycles (simulating 14 days). Surface roughness, modulus of elasticity in bending, and spectrophotometry were used to assess the effect of aging on TOAs.

Results

After 1000 thermocycles, Duran+ had the highest modulus of elasticity and differed statistically from all other groups. The intragroup comparison showed that only Duran+'s elastic modulus significantly changed after 1000 thermocycles in comparison with the control group. Surface roughness values (Ra), did not statistically differ among brands or thermocycling group measures. The change in chemical properties was not significant in any brand.

Conclusion

One-layer PETG (Duran+) failed to demonstrate stability after in vitro aging, thus suggesting that clinicians should be aware of the change in mechanical properties when using one-layer PETG (Duran +) in a 2 weeks regime.

Dimensional Stability and Reproducibility of Varying FFF Models for Aligners in Comparison to Plaster Models

To test the impact of FFF filaments, printing parameters, thermoforming foils, repeated thermoforming cycles, and type of jaw on the dimensional stability of FFF models for aligners and to compare them with plaster models, FFF models (maxilla, n = 48; mandible, n = 48) from two filaments (SIMPLEX aligner and Renfert PLA HT, both Renfert GmbH) were fabricated using four printing parameters (one, two, or three loops; four loops acted as the default) and conventional plaster models (n = 12) based on a young, female dentition. All models were thermoformed under pressure three times in total using two different thermoforming foils, namely 0.75 mm × 125 mm Ø aligner foil (CA Pro+ Clear Aligner, Scheu Dental) and 1.0 mm × 125 mm Ø Duran foil (Duran+, Scheu Dental). Aligner foil was heated at 220 °C for 25 s and Duran foil at 220 °C for 30 s. All models were scanned after fabrication as well as after each thermoforming cycle. The obtained STL datasets were analyzed using the local best-fit method (GOM Inspect Pro, Carl Zeiss Metrology GmbH). Data were analyzed using a Kolmogorov-Smirnov-test, a one-way ANOVA with post-hoc Scheffé, and a t-test (p < 0.05). The dimensional stability of the models was most strongly affected by the printing parameters (number of loops; η_p² = 0.768, p < 0.001) followed by the thermoforming foil used (η_p² = 0.663, p < 0.001) as well as the type of model (η_p² = 0.588, p < 0.001). In addition, various interactions showed an influence on the dimensional stability (η_p² = 0.041-0.386, p < 0.035). SIMPLEX maxillary models (default; four loops), thermoformed using aligner foil, showed higher deformation stability than did plaster models. These initial FFF models provide comparable precision to plaster models, but the dimensional stability of the FFF models, in contrast to that of plaster models, decreases with increasing numbers of thermoforming cycles.

Resistance of PETG Materials on Thermocycling and Brushing

The aim was to assess the impact of thermocycling and brushing on the surface roughness and mass of PETG material-the most commonly used for orthodontic retainers. A total of 96 specimens were exposed to thermocycling and brushing with three different kinds of toothbrushes depending on the number and thickness of the bristles. Surface roughness and mass were evaluated three times: initially, after thermocycling, and after brushing. In all four brands, both thermocycling and brushing increased surface roughness significantly (p < 0.001), with Biolon having the lowest and Track A having the highest. In terms of brushing, only Biolon samples showed statistically significant increased roughness after brushing with all three types of brushes, in comparison to Erkodur A1, where differences were not statistically significant. Thermocycling increased the mass of all samples, but a statistically significant difference was found only in Biolon (p = 0.0203), while after brushing, decreased mass was found in all specimens, statistically significant only in Essix C+ (CS 1560: p = 0.016). PETG material showed instability when exposed to external influences- thermocycling produced an increase in roughness and mass, and brushing mostly caused an increase in roughness and decrease in mass. Erkodur A1 demonstrated the greatest stability, whereas Biolon demonstrated the lowest.

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.

Evaluation of Mechanical Properties of Different Thermoplastic Orthodontic Retainer Materials after Thermoforming and Thermocycling

While the durability of thermoplastic aligners has been the subject of numerous studies, the durability of thermoplastic retainers has received significantly less attention. Patients are often advised to wear their thermoplastic retainers indefinitely, so the durability of the materials used in their fabrication is crucial to determining whether they are worth the cost. Limited studies have evaluated the properties of thermoplastic retainer materials and the effects of thermocycling on their mechanical properties. Thus, this study aimed to examine six thermoplastic retainer materials after thermoforming with and without thermocycling. The materials' flexural modulus, hardness, and surface roughness values were measured after thermoforming (Group 1) and after thermoforming with subsequent thermocycling for 10,000 cycles (Group 2). After thermoforming, there was a significant difference in flexural modulus and hardness values between most of the materials. However, their surface roughness was not significantly different (p < 0.05). After thermocycling, the flexural modulus and hardness increased significantly for most tested materials (p < 0.05) compared to Group 1. Concerning the surface roughness, only two materials showed significantly higher values after thermocycling than Group 1. Thus, all the mechanical properties of the evaluated materials differed after thermoforming, except the surface roughness. Moreover, while thermocycling made the materials stiffer and harder in general, it also made some of them rougher.

Stress and movement trend of lower incisors with different IMPA intruded by clear aligner: a three-dimensional finite element analysis

BACKGROUND

During the intrusion of lower incisors with clear aligners (CAs), root disengagement from the alveolar bone often occurs, resulting in serious complications. This study aimed to determine the potential force mechanism of the mandibular anterior teeth under the pressure of CA, providing theoretical data for clinical practice.

METHODS

In this study, a 3D finite element model was established, including the CA, periodontal ligament, and mandibular dentition. Incisor mandibular plane angles were set as 5 groups: 90°, 95°, 100°, 105°, and 110°. The 4 mandibular incisors were intruded by 0.2 mm, while the canines were the anchorage teeth. The stress, force systems, and potential movement trends of mandibular anterior teeth were obtained.

RESULTS

The compressive stress of the incisors was concentrated in the lingual fossa, incisal ridge, and apex. With the increase in IMPA, the moment of central incisors changed from lingual crown moment to labial crown moment, with the turning point between 100° and 105°, but the center of resistance (CR) was always subjected to the force toward the lingual and intrusive direction. The force and moment toward the labial side of the lateral incisors were greater than those toward the central incisors. The canines always tipped distally and received extrusive force with no relationship with IMPA.

CONCLUSIONS

With the increase in the initial IMPA, the direction of labiolingual force on the mandibular incisors was reversed. However, the root of the lower incisors always tipped labially, which indicated fenestration and dehiscence.

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.

Occlusal Plane Modification in Clear Aligners Treatment: Three Dimensional Retrospective Longitudinal Study

The purpose of the present study was to evaluate: (i) maxillary occlusal plane changes after clear aligners therapy with a 3D measurement technique; and (ii) as a secondary outcome, if such changes were correlated to the patient’s 1axilla-mandibular divergence. 3D maxillary models of 32 patients (7 males and 25 females; mean age 22.3 +/− 3.4 year) treated with clear aligners were analyzed. The angle (α) between a reference palatine plane and a maxillary occlusal plane was measured. Five angular cephalometric measurements (NSL/MP; PP-OP; OP-MP; PP-MP; PFH/AFH%) were performed and related to Δα. The subjects were further divided into three groups according to facial divergence. After aligner treatment, Δα increased in hyperdivergent patients and decreased in hypodivergent patients (p < 0.05). Δα showed a significant positive correlation with NSL/MP (rho = 0.44) and negative correlation with PFH/AFH% (rho = −0.53). Aligners treatment produced a counterlockwise rotation of the maxillary occlusal plane, even if this rotation occurs differently depending on divergence.

An In Vivo Study on the Development of Bacterial Microbiome on Clear Orthodontic Retainer

OBJECTIVES

The objective of this study was to see how the bacterial composition changes on clear orthodontic retainer over a 14-day period.

METHODS

Saliva and plaque samples collected from a clear retainer surface were obtained from five healthy volunteers receiving retainer treatment. Prior to clear retainer delivery, patients had not been wearing any other appliances. Patients were instructed to wear their clear retainer for the 14-day period, taking them off to eat and to clean them with a soft-bristle toothbrush. The bacterial composition was determined via Illumina MiSeq sequencing of the bacterial 16S rRNA. After bioinformatics processing using the QIIME pipeline, the intra- and intergroup biodiversity of the sample was analyzed.

RESULTS

The bacterial composition changed over a 14-day period in the saliva and on the clear retainer. When comparing the different phylum levels between saliva and clear retainer' microbiota, the Firmicutes were significantly increased 1.26-fold (p = 0.0194) and 1.34-fold (p = 0.0123) after 7 and 14 days of retainer treatment when compared to saliva, respectively. The Campylobacteriota were significantly decreased 1.80-fold (p = 0.05) in the clear retainer when compared to saliva at 7 days. At the genus level, several microbiota were significantly increased in relative abundance in the clear retainer after the 14-day period.

CONCLUSION

These findings reveal that the presence of a clear retainer in the mouth might lead to enamel changes or periodontal tissue destruction, especially after 14 days of use.

Effects of upper-molar distalization using clear aligners in combination with Class II elastics: a three-dimensional finite element analysis

INTRODUCTION

The effects of upper-molar distalization using clear aligners in combination with Class II elastics for anchorage reinforcement have not been fully investigated yet. The objective of this study is to analyze the movement and stress of the whole dentition and further explore guidelines for the selection of traction methods.

METHODS

Three-dimensional (3D) finite element models are established to simulate the sequential molar distalization process, including the initial distalization of the 2^nd molar (Set I) and the initial distalization of the 1^st molar (Set II). Each group set features three models: a control model without Class II elastics (model A), Class II elastics attached to the tooth by buttons (model B), and Class II elastics attached to the aligner by precision cutting (model C). The 3D displacements, proclination angles, periodontal ligament (PDL) hydrostatic stress and alveolar bone von Mises stress in the anterior area are recorded.

RESULTS

In all of the models, the maxillary anterior teeth are labial and mesial proclined, whereas the distal moving molars exhibit distal buccal inclination with an extrusion tendency. With the combination of Class II elastics, the anchorage was effectively reinforced; model C demonstrates superior anchorage reinforcement with lower stress distribution in comparison with model B. The upper canines in model B present an extrusion tendency. Meanwhile, the mandibular dentition in models B and C experience undesired movement tendencies with little discrepancy from each other.

CONCLUSIONS

Class II elastics are generally effective for anchorage reinforcement as the upper-molar distalization is performed with clear aligners. Class II elastics attached to an aligner by precision cutting is a superior alternative for maxillary anchorage control in cases that the proclination of upper incisors and extrusion of upper canines are unwanted.

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.

Structural Conformation Comparison of Different Clear Aligner Systems: An In Vitro Study

The aim of this study was to evaluate the structural conformations of three clear aligner systems, Eon^®, SureSmile^®, and Clarity^®, and compare them with the most commonly used system, Invisalign^®. Clear aligner samples from Invisalign^®, Eon^®, SureSmile^®, and Clarity^® were cut into 5 × 5 mm squares and exposed to artificial saliva for 2 weeks. The specimens were then subjected to a Vickers hardness test by applying three separate indentations with a 25 gf load for 15 s. Hardness was calculated using the following formula: Vickers hardness number = 1.854 (F/D2). Fourier transform infrared spectroscopy (FTIR) analysis was performed, with a diamond hemisphere and infrared beam being allowed to pass through each specimen. A mid-infrared range from 4000 to 375 cm⁻¹ was recorded. The samples were also evaluated using scanning electron microscopy (SEM) combined with energy-dispersive X-ray microanalysis spectroscopy at different magnifications. No statistically significant differences were observed between the included systems with regard to hardness. All systems showed a polyurethane-based material, as illustrated by the FTIR analysis. Some structural variations were noted in the Invisalign^® system, which had a more homogeneous architecture. Statistically significant differences in the carbon weights were found among the systems. The four systems presented comparable hardness levels. Mild molecular composition differences were found, but all systems had the similarity of being composed of a polyurethane-based material. Carbon and oxygen were the main elements, as they were located in all studied clear aligners. The SEM analysis revealed that Invisalign^® had a smoother surface than the other three systems. All included clear aligners had similar characteristics with minimal differences, providing a wide variety of options for clinical orthodontic treatment according to patients’ demands.