How Invisalign is made

The manufacturing of Invisalign, a popular brand of clear orthodontic aligners, involves a combination of advanced 3D imaging technology, precise computer-aided design (CAD), and computer-aided manufacturing (CAM) processes. Here's an overview of the steps involved:

1. Dental Impressions and Scanning:

- The process begins with the dentist taking dental impressions or intraoral scans of the patient's teeth.

- These impressions or scans are then converted into a detailed 3D digital model of the patient’s teeth.

2. Treatment Planning:

- Using specialised software, Invisalign technicians, along with the orthodontist or dentist, develop a treatment plan. This plan maps out the desired movement of the teeth from their current position to the final desired position.

- The software creates a series of stages between the current and desired teeth positions.

3. 3D Printing of Aligner Molds:

- For each stage of the treatment plan, a separate 3D printed mold is created. These molds are precise representations of how the teeth should look at each stage.

- State-of-the-art 3D printing technology is used to fabricate these molds, ensuring high accuracy.

4. Creating the Aligners:

- The actual aligners are then manufactured using a medical-grade thermoplastic material.

- This material is carefully chosen for its clarity, strength, and flexibility.

- The plastic sheet is placed over the 3D printed mold and subjected to a combination of heat and pressure to form the aligner.

5. Trimming and Finishing:

- After the aligner is formed, it is trimmed to a custom fit for the patient's gum line. This is important for comfort and effectiveness.

- The aligners are then polished and finished so that they are smooth and clear.

6. Quality Check and Packaging:

- Each aligner undergoes a quality check to ensure it meets the necessary standards.

- The aligners are then packaged and sent to the dentist, along with the patient’s treatment plan.

7. Series of Aligners:

- Patients receive a series of aligners, each to be worn for about one to two weeks before moving on to the next in the series.

- Each aligner makes slight adjustments to the position of the teeth, according to the planned movement.

8. Regular Monitoring:

- Throughout the treatment, the patient will have regular check-ups to monitor progress and make any necessary adjustments.

Invisalign aligners offer a discreet and comfortable alternative to traditional braces, using advanced technology to create a customised treatment plan for effective teeth straightening.