Sustainability

The most commonly used technology in the production of orthodontic aligners, known as thermoformed aligners, was developed in 1997. This technology requires a prior 3D model impression, which is then thermoformed with plastic made from various types of polymers to create the aligner.

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The traditional production flow includes the following steps: receipt of the 3D intraoral scan, digital treatment planning in software (CAD), 3D printing of prototypes in resin, and finally thermoforming and cutting of the aligners.

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A serious problem with thermoformed aligners is the millions of resin dental models that are produced each year, both in-house and by manufacturers, for the production of aligners. Unfortunately, resin models are not recyclable, adding a major burden to an already stressed environment

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However, recent advances in orthodontics have introduced a disruptive technology known as direct aligner printing, which utilizes shape-memory polymers. This technology offers numerous advantages over the traditional thermoformed aligner workflow:

 

1. Environmental Impact: The accumulation of non-recyclable printed dental models poses a significant environmental problem. Directly printed aligners could offer a solution, eliminating the need for dental models. Moreover, materials used in direct 3D aligner printing are considered more environmentally friendly. The environmental impact is significantly reduced, as the number of aligners needed for orthodontic movement with direct 3D printing is three times less than the conventional model. As aligners are replaced every 14 days, the environmental impact becomes a concerning issue. The traditional method neglects the environmental impact caused by millions of printed dental models. The new technology not only reduces production costs but also lessens environmental costs. It consumes less energy, decreases carbon emissions, and generates no plastic waste after cutting thermoformed aligners. The carbon footprint resulting from a thermoformed aligner is approximately 4 kg of CO2, while a directly printed aligner produced through disruptive technology is only 1.8 kg of CO2.

2. Efficiency: Direct aligner printing eliminates steps such as model printing and thermoforming, making it a faster procedure. This allows for swift delivery of the aligner(s) to the patient.

3. Cleaner Environment: The thermoforming procedure generates dust, creating a dirty office environment and posing risks to personnel. In contrast, printed aligners are manufactured in a dust-free environment.

4. Accuracy: Printed aligners offer greater adaptation accuracy compared to plastic films often used in orthodontic offices through the thermoformed method. Fit accuracy is crucial for effective treatment.

5. Uniform Thickness: Printed aligners maintain a consistent thickness, providing uniform forces to all teeth. Thermoformed aligners may experience reduced thickness after the thermoforming procedure.

6. Versatility: Unlike thermoformed aligners, printed aligners allow for variable thickness in specific areas. The CAD software can add extra thickness only to the areas where teeth are being moved, offering versatility in treatment.

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Direct aligner printing, based on 3D printing of shape memory materials, is a promising advancement in clear aligner therapy. The implications include a potential reduction in the cost of treatment and its environmental impact.

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Consumers don't necessarily want the leading manufacturer of clear aligners; they desire the treatment modality and all the benefits it provides. And when we talk about benefits, this new technology is filled with them.