Direct printed aligners improve customization and precision in orthodontics, suggesting a shift in treatment methods.
Direct Printed Aligners (DPAs), manufactured via stereolithography (SLA)/digital light processing (DLP) 3D printing directly from digital models, represent a major advance in clear aligner therapy. By eliminating thermoforming, they offer enhanced precision, speed, and customization using UDMA resins for controlled tooth movement. Key benefits include chairside fabrication and waste reduction. However, limitations persist around material biocompatibility, anisotropic behavior, surface roughness, and torque control. Future breakthroughs in smart materials, AI prediction, and multi-material printing are expected to address these challenges and drive the personalization of orthodontics.
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Shahana et al. (2025) studied this question.
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