Proof-of-Concept Digital-Physical Workflow for Clear Aligner Manufacturing.

ABSTRACT: Background/Objectives: Clear aligner therapy has become a mainstream alternative to fixed orthodontics due to its versatility. However, the variability in thermoforming and the limited validation of digital workflows remain major barriers to reproducibility and predictability. Methods: This study addresses that gap by presenting a proof-of-concept digital workflow for clear aligner manufacturing by integrating additive manufacturing (AM), thermoforming simulation, and finite element analysis (FEA). Dental models were 3D-printed and thermoformed under clinically relevant pressures (400 kPa positive and -90 kPa negative). Results and Discussion: Geometric accuracy was quantified using CloudCompare v2.13.0, showing that positive-pressure thermoforming reduced maximum devi

SUBMITTER: Huang SH 

PROVIDER: S-EPMC12563393 | biostudies-literature | 2025 Oct

REPOSITORIES: biostudies-literature