The process of making custom aligners is complex and involves many steps. It starts with a computer-generated impression of the patient’s teeth, which is first scanned to create a 3D model. This digital representation of the impressions is then processed by technicians on specialized software that converts it into an STL file, which can be used for manufacturing.

The STL files are sent to our 3D printer where they are printed out as hundreds of tiny little plastic triangles that will eventually be molded together into one complete aligner tray. Once all the pieces have been printed, they are placed in an oven at 275 degrees Fahrenheit for 40 minutes before being cooled down overnight with air jets to avoid warping or distortion during the cooling process.

Here are 5 reasons why the design process of clear aligners makes Invisalign clear aligners unique:

1. Better aesthetics

3-D scanners and printers are able to recreate the precise tooth color and translucency of your natural teeth, including any variation in shading between front and back teeth. This is a crucial step for achieving optimal results – because we want our patients not only to feel confident about their smile, but we also want them to be absolutely satisfied with how it looks.

2. Better fit

Digital imaging provides us with an incredibly accurate picture of each patient’s unique smile – which leads to better treatment planning as well as improved overall fit. We are able to capture important details like gingival contours or tooth curvatures that cannot be detected by traditional impressions alone.

3. Better function

Patients often report that their teeth feel more comfortable and function better once they start wearing their aligners. This is because our 3D printers are able to create very precise aligners that gently guide your teeth into their correct positions.

4. Customized treatment

Since each patient’s needs are unique, we are able to manufacture custom-fit aligners for each one. This also allows us to provide a wide range of treatment options, including both mild and severe cases of misalignment.

5. Better results

Invisalign clear aligners are up to three times more effective than traditional alternatives. It is important to keep in mind that our patients should expect a visible improvement in appearance, but the true clinical benefits of using Invisalign can only be measured through regular checkups at our practice.

The design process of clear aligners is what sets Invisalign apart from other clear aligner products on the market. If you’re considering braces or Invisalign, be sure to ask your dentist about the advantages of 3D printing technology!


As you can see, the process of making custom aligners is a complex one that requires a lot of precision and care. But the end result is a product that is able to deliver precise and comfortable dental alignment for patients. If you are interested in getting Invisalign clear plastic aligners, contact us today. We would be happy to help you straighten your teeth or solve other dental issues you may have so that you have that beautiful smile. If you’re interested in reading more about the comparison of braces and invisalign then make sure to keep reading.

By Hemant Kumar

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