Dentistry

The next big thing in clear aligner therapy: Enhancement of the digital workflow

15^th Euro Congress on Dental & Oral Health

October 24-26, 2016 Rome, Italy

Sherif Kandil

K Line Europe, Germany

Posters & Accepted Abstracts: Dentistry

Abstract:

Introduction: Clear aligner therapy has been developing recently thanks to the advancements in CAD/CAM software. The standard method of clear aligners' manufacturing comprises undertaking tooth movements on dental digital models with specialized software, then 3D printing of physical prototypes and finally fabricating the aligners through vacuum (thermoforming) technique. This method has its limitations being lengthy, costly, requiring human intervention in addition to some material waste. We introduce a new methodology of fabricating aligners in a completely digital platform and in a fast, inexpensive manner with minimal human intervention and least material consumption. Objectives: The objectives of the present study are: To exploit the advancing CAD/CAM technology in digital dentistry via producing 3D-printed clear aligners; to produce the largest number of clear aligners in short duration; to introduce a cost-effective method of fabrication of clear aligners with minimal material waste and to eliminate human intervention in clear aligners' manufacturing. Materials & Methods: Digital models were prepared with data processing and subsequent teeth segmentation on orthodontic software (Ortho Analyzer by 3shape). Tooth movement was carried out and subdivided onto sub-setups. Each sub-setup was installed in another facility of the software (Splint Designer). A splint was designed for each digital sub-setup with thickness less than 1 mm similar to clear aligners. At the end of designing, the splint's margins were smoothened using finishing tools in the software. Each splint (aligner) was 3D printed with a variety of material, each with different transparency, strength, flexibility and biocompatibility properties (basically, in soft and rigid forms). The produced aligners were made in different colors to allow for inspection of finishing of their margins. Results: Different aligners with different colors could be produced using this method. Each aligner had different strength, clarity & flexibility and biocompatibility properties. Rigid aligners had good strength but low elasticity; soft ones had better adaptation, resistance to fracture but less strength. Aligners' margins were finely smoothened without any intervention of lab personnel. The aligners were not clinically tested. Conclusion: Using CAD/CAM technology, clear aligners could be produced in a completely digital fashion with computer-assisted designing and 3D printing. The 3D-printed aligners were produced in relatively short duration compared to the vacuum method; however, designing a splint for each movement sub-setup is still time consuming. The given methodology was very cost-effective compared to the standard thermoforming method (cost of models and sheets was eliminated) with much less material waste. Human intervention was eliminated as the designing and finishing were done digitally.

Biography :

Email: s.kandil@kline-europe.de