Transforming Orthodontics with Three-dimensional Printing: Current Trends and Future Directions—A Review

The integration of three-dimensional (3D) printing technology has profoundly transformed contemporary orthodontic practice by enabling highly customized, precise, and efficient digital workflows. This review aims to provide a comprehensive overview of the evolution, principles, clinical applications, and future prospects of 3D printing in orthodontics. The transition from conventional plaster models and laboratory-dependent procedures to digital intraoral scanning, computer-aided design and manufacturing (CAD–CAM), and additive manufacturing has enhanced diagnostic accuracy, treatment predictability, and patient comfort while reducing chairside time and laboratory turnaround. Various 3D printing technologies, including stereolithography, fused deposition modelling, digital light processing, selective laser sintering, and PolyJet printing, are discussed with respect to their orthodontic applications, advantages, and limitations. Current clinical uses encompass printed study models, aligners, customized brackets, archwires, functional and expansion appliances, surgical splints, fixation plates, and presurgical nasoalveolar molding devices. Recent advances such as compliance-monitoring appliances, integration of artificial intelligence, and emerging concepts of 4D printing further highlight the expanding scope of this technology. Despite challenges related to material properties, cost, regulatory approval, and long-term clinical validation, 3D printing represents a paradigm shift toward fully digital, patient-specific orthodontic care.