Aesthetic treatment with in-house aligners

After thoroughly reviewing and confirming the virtual treatment set-up, we received STL files for each step of the aligner sequence. The digital models were then printed in-house using the SprintRay Pro 2 3D printer (Fig. 10). The entire set of ten models was printed in approximately 1 hour and 30 minutes, demonstrating the efficiency of chairside 3D-printing technology. Postprocessing followed in two quick and effective steps: placement in the washing unit for 11 minutes and then in the curing unit for 1 minute and 22 seconds (Fig. 11). This rapid workflow allowed us to complete and prepare the models for thermoforming within the same day.

Aligner fabrication and treatment delivery

Using a thermoforming machine, the aligners were fabricated on the printed models (Figs. 12–15). Composite attachments were bonded to specific teeth according to the digital set-up to enhance the effectiveness of specific movements (Figs. 16–18).

The patient was instructed to wear each aligner for ten to 14 days, depending on fit and comfort, and to follow up regularly for assessment. After completion of the tenth aligner, a final appointment was scheduled for the removal of the attachments and delivery of the night-time retainer.