Dental labs produce custom aligners using 3D printing by first gathering precise 3D scans of a patient’s teeth. Instead of relying on conventional impression trays, dentists use advanced digital scanning devices to capture detailed digital replicas of the mouth. These virtual tooth representations are then transmitted to the lab to the dental laboratory, where lab technicians utilize specialized orthodontic planning software to map out the gradual tooth movement over the course of treatment. The software segments the correction process into multiple steps, with each step representing a specific phase of dental repositioning.

Once the treatment plan receives final approval from the dentist, the lab generates the production-ready STL files for 3D printing. Using a high-precision industrial 3D printer, the lab produces a complete series of physical models, each matching a specific alignment phase. These models are fabricated from biocompatible dental resin, chosen for its structural integrity and biocompatibility to ensure safe intraoral contact.

After printing, the lab drapes a thin, transparent thermoplastic sheet over each model. Through a process involving controlled heat application and vacuum forming, the material molds flawlessly around each tooth position to create a custom-fitted aligner. Each aligner is then hand-finished and surface-treated for hygiene to ensure a seamless oral experience. The aligners undergo multi-point accuracy checks before being individually packaged and dispatched to the treating clinic for patient distribution.

This entire workflow enables exact personalization while maintaining exceptional consistency. Since every aligner is generated from CAD data, each aligner remains identical to its digital counterpart, and rapid modifications can be implemented if the patient requires a mid-course correction. Additionally, 3D printing replaces weeks of manual work with hours of automation, allowing patients to receive their aligners sooner. As additive manufacturing advances, laboratories are perfecting this process to deliver next-generation aligners that combine speed, fit, and clinical excellence.