Aligners: Outsource or produce in-house?

In-house production of aligners

Some practices are adopting an in-house model in which treatment planning and aligner production take place within the practice. This approach can provide greater control over diagnostics, treatment planning and production, while allowing the workflow to be adapted more readily to the individual patient’s needs. Potential advantages of in-house production include:

• shorter planning and production times, particularly when digital tools such as DDP AI, DDP-Ortho and the DTS Aligner Planner module (Polorto) are integrated into the workflow;
• direct involvement of the treating clinician in the treatment plan, supported by artificial intelligence and the Smart Set-up feature;
• easier adaptation of treatment to the patient’s needs, including adjustments during therapy;
• greater control over case-related costs, based on the number of aligners and services required;
• the ability to reproduce lost aligners or retainers without returning the case to an external supplier;
• greater independence from external providers and flexibility in selecting materials and production procedures;
• direct oversight of appliance quality, supported by appropriate training and quality-control procedures; and
• the option of offering aligners under the practice’s own branding.

“As a dental professional practising orthodontics, I leverage technologies that maximise treatment efficiency and patient comfort. With the DDP Systems workflow, we can produce aligners directly in the clinic, maintaining full control over diagnostics, treatment planning and individualised therapy, ensuring predictable and safe outcomes,” said Dr Szymon Budziński, a Polish dentist.

However, in-house production also requires suitable equipment, trained personnel, staff time and established production and quality-control procedures. The most appropriate workflow therefore depends on the clinician’s experience, the practice’s capabilities, case volume and organisational factors. Many practices adopt a hybrid model, completing selected cases in-house while outsourcing others.

Digital workflow for in-house aligner production

Diagnostic model—DDP AI
The workflow begins with the creation of an advanced digital diagnostic model from a standard intra-oral scan. DDP AI processes the scan data and prepares the model for subsequent diagnostic analysis and treatment planning.

Treatment planning—DDP-Ortho
DDP-Ortho supports the diagnostic and clinical treatment-planning stage. The software also includes the Smart Set-up feature. Its functions include:

• diagnostic analysis and evaluation of the digital model;
• cephalometric analysis;
• identification of the malocclusion and planning of different treatment variants;
• virtual set-up and visualisation of treatment goals; and
• communication of the proposed treatment outcome to the patient.

Technical production—DTS Aligner Planner
The DTS Aligner Planner module supports the technical preparation of models for aligner production. Its functions include:

• selection of the required working models;
• detailed planning of tooth movements;
• adjustment of movement sequences and ranges;
• planning of interproximal reduction; and
• export of three-dimensional working models for printing.

Individual technical stages can be assigned to appropriately trained members of the practice team or to an external laboratory. However, the treating clinician must retain responsibility for diagnosis, treatment planning and clinical monitoring.

Choosing the appropriate aligner production model

The question of whether to outsource aligner production or bring it in-house is not solely a matter of technology; it also reflects a philosophy of care. For clinicians seeking greater control over the therapeutic process, an in-house model can provide more direct influence over treatment planning and the tools and procedures used. Digital ecosystems have made in-house aligner production increasingly accessible to a growing number of practices, offering greater flexibility, closer cost control and the ability to adapt treatment more readily to individual cases. Further information about Polorto’s digital planning solutions is available on the company’s website.