Advances in computer-aided design and 3D printing are reshaping orthodontic workflows. A review of 69 studies (2010–2020) highlights how custom appliances such as brackets, aligners, retainers, surgical splints, and nasoalveolar molding devices can now be produced layer by layer with precision. Technologies including stereolithography, digital light processing (DLP), fused deposition modeling (FDM), PolyJet, and selective laser sintering (SLS) are leading the way in this transformation.
Key insights
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Digital workflow reduces traditional steps: Intraoral scanning replaces physical impressions and gypsum casts, enabling a fully digital process.
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High accuracy for models and splints: 3D-printed orthodontic models, especially those produced using PolyJet and DLP, meet clinical precision standards. Accuracy often depends on factors such as layer thickness and base design.
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Aligners and retainers: Directly printed aligners using materials like Dental LT resin offer strong geometric fidelity. Printed Essix-style retainers perform comparably to traditionally fabricated options.
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Customized appliances and auxiliaries: Patient-specific components such as impacted tooth chains, bespoke brackets, and miniscrews are now viable for in-practice or lab-based production.
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Orthognathic devices and molding plates: 3D-printed surgical splints and nasoalveolar molding plates are proving as accurate and effective as conventional versions, often helping reduce the number of clinical appointments required.
Implications for practice
For clinicians and labs, 3D printing offers:
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Streamlined, digital-first workflows that reduce time and costs
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Greater freedom to design and manufacture personalised treatment appliances
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Opportunities to integrate future innovations, such as multi-material printing or drug-releasing retainers
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A competitive advantage as orthodontic materials and digital standards continue to evolve