Clear aligners are rapidly becoming the preferred alternative to traditional metal braces, and many companies are exploring offering clear aligners under their own brand. However, the clear aligner manufacturing is a complex and meticulous undertaking, requiring multiple steps and stringent quality control.
In this article, we will guide you through the clear aligner manufacturing process and help you choose the right manufacturer to partner with.
Contents
1. How Clear Aligners Are Made at Dental Labs?
1.1. Digital Treatment Design
The process starts with a treatment plan developed by experienced dental technicians, dentists, and orthodontists. The plan determines how the patient’s teeth will move, following clinically validated protocols to ensure effectiveness and accuracy. This digital plan is then converted into STL files for further processing.
1.2. 3D Printing
Once the treatment plan is finalized, 3D printing technology is used to create solid dental models for each treatment stage. High-precision stereolithography (SLA) printers are employed to produce models with exceptional accuracy, forming the foundation for the next steps.
1.3. Thermoforming
The core of clear aligner production is thermoforming. Biocompatible thermoplastic sheets are heated and vacuum-formed over the 3D-printed dental models, ensuring a precise fit. The choice of material plays a crucial role in the aligner’s durability, effectiveness, and patient comfort.
1.4. Laser Marking
For traceability and quality control, each aligner undergoes laser marking with a unique identification code. This step ensures that each aligner can be tracked through the entire manufacturing and distribution process.
1.5. Trimming & Polishing
After thermoforming and marking, the aligners go through an automated trimming and polishing process:
- Trimming is done according to the required specifications, with options for scalloped or straight-cut trimlines.
- Polishing ensures the aligners have a smooth surface, providing maximum comfort to the patient.
1.6. Quality Control
Every aligner undergoes a rigorous inspection to eliminate defects and ensure:
- Proper fit and transparency.
- Structural integrity (checking for cracks or inconsistencies).
- Precision in tooth movement sequencing.
1.7. Packaging & Shipping
After passing quality checks, staff sanitize, sort, and package the aligners. Dental lab provides:
- Custom-branded and unbranded packaging for private-label solutions.
- Individually sealed aligner packets for patient convenience.
- Branded aligner kits that include trays, chewies, and removal tools.
Learn more about Choosing the Right Retainer Materials
2. Why Choose XDENT LAB as Your Manufacturing Partner?
2.1. Advanced Manufacturing & Quality Assurance
XDENT LAB – Vietnam Dental Lab utilizes cutting-edge digital workflows to ensure efficiency and consistency. Our ISO-certified quality management system guarantees that every aligner meets the highest industry standards.
2.2. Competitive prices
XDENT LAB offers the most affordable production cost in the clear aligner manufacturing market worldwide. Using our production service will help your business save maximum costs and increase profits.
2.3. Quickly delivered
With a professional team and an advanced manufacturing process, XDENT LAB always responds to our partners’ requests as quickly as possible. XDENT LAB ensures that our partners will get productions without delays, allowing them to continue working uninterrupted.
2.4. Large production possibility
XDENT LAB uses a digital workflow and laser aligner cutter technology to support the production activity. Therefore, when our partners use the service, we ensure to satisfy their manufacturing requirements.
2.5. Dedicated care
XDENT LAB has a team of experienced staff from production to customer care. We always bring our core values of “Kindness- Compliance – Dedication – Speed – Saving” to provide services to our partners.
2.6. Expertise in Removable Dentures
In addition to clear aligners, XDENT LAB specializes in removable dentures, providing high-quality outsourcing solutions to dental labs in the USA. Our expertise in both clear aligners and removable prosthetics makes us a one-stop solution for labs seeking scalable production with superior quality.
For more information aboutXDENT LAB – Dental Laboratory Vietnam
3. Conclusion
The Clear Aligner Manufacturing Process involves multiple intricate steps, from digital treatment planning to quality assurance and packaging. By partnering with XDENT LAB, dental labs can offer premium-quality clear aligners and removable dentures without the burden of setting up a costly in-house production facility.
For dental labs looking to scale their clear aligner business, XDENT LAB provides a reliable, high-quality, and customizable solution.
Contact us today to learn how we can support your lab-to-lab clear aligner production needs!
