How to make clear aligner

Thermoform

It explains know-how for thermoforming, cleaning and packing.

Thermoforming process

Thermoforming > trimming > polishing/cleaning

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Item

Pressure forming

Vacuum forming

Pressure

Principle

Strength and weakness

Expensive 

High forming quality

Cheap 

Low forming quality

4~6 bar

Select forming equipment

Minimum specification:

pressure 4 bar or more

 

Sheet selection criteria

There are 3 types of sheet depending on the thickness of the product.

Clear aligner is a device for oral use, and the sheet must be a certified medical device. Medical device certified products have no problem with treatment. The difference between high and low prices is due to difference in product characteristics such tensile strength depending on raw materials and manufacturing processes. Products with good characteristics are expensive products, and have positive effects such as wearing comfort and shortening the treatment period.

Item

Soft

Medium

Hard

Thickness

0.5mm

(0.020inch)

0.625mm

(0.025inch)

0.75mm

(0.030inch)

Tooth movement range

0.6~1.0mm

0.4~0.6mm

0.2~0.4mm

Image

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Blockout

In case sheet does not fall out by undercuts, or in case sheet is torn by sharp edges,

it is task of supplementing the model with resin for blockout or with heating-resistant material

A typical case of blockout

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Gums are high

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Adjust pellet

Adjusting to fit gums

Print model low

Adjusting to fit gums

Thermoforming method

Ensure that the height of model being molded is only up to the gums that will be used as devices.

If it is too high, the sheet stretches a lot and becomes thin, and a device of uniform thickness cannot be made.

Use a height-adjustable equipments, or adjust the base height carefully printing.

 

Precautions when removing devices

To prevent deformation or tearing of the device, remove unnecessary parts as much as possible in advance, and do not remove them all at once, but remove the rearmost molar part little by little.

 
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TIP : Use curved scissors. You can easily cut to fit the arch line    using curved scissors.

Trimming

Please cut 2~4mm below the margin using curved scissors.

 

Trimming area

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Strength and weakness

Little force transmitted

No foreign body feeling

Strength and weakness

Lot force transmitted because there are many parts to wrap

May feel foreign body

Along margin line

Straightly 2~4mm below margin line

 
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Polishing & cleaning

Smoothly round the sharp part of the cut section, clean to remove foreign objects and bacteria.

TIP :

When polishing with handpiece, it must move in one direction along the direction of rotation of the wheel.

When cleaning with air, be careful that the device may be deformed if too strong force is applied.