How Aligners Are Made
Invisalign state-of-the-art digital scanning and computer-aided design, dentists or orthodontists create a treatment plan that maps out your teeth’s movements until they reach their final position. This treatment plan is then used to create a series of clear plastic aligners that are customized to your unique smile. These aligners are molded via thermoforming on customized 3D-printed casts, with smartly designed BPA-free medical-grade plastic that is firm enough to apply pressure to your teeth, but flexible enough to feel comfortable in your mouth.
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The first step in producing the thermoformed clear aligners is to obtain a digital impression (also known as a model). This is then sliced into a number of horizontal layers, and each individual layer represents a cross-section of the dental model. Each layer is then modeled with a separate piece of custom-printed thermoplastic resin. This allows for more detailed and precise control over the desired aligner thickness, extension, attachments, etc.
The aligners are then trimmed and polished for a more comfortable fit in the mouth, and they’re laser marked with the patient’s name. Finally, they’re bagged and boxed up, ready for patients to start their journey towards a healthier smile!