Reimagining Aligner Therapy: Advanced Features Unlocked by Direct 3D Printing

In the world of orthodontics, aligners have come a long way from their early days as a “cosmetic” alternative to brackets. Today, they’re a powerful clinical tool—if the right technology is behind them. Traditional thermoformed aligners, while useful, have long been limited by material constraints and one-size-fits-all design approaches.

But with the rise of direct 3D printing, especially innovations pioneered by LuxCreo, aligner therapy is entering a new era—one defined by greater precision, personalization, and performance.

Reducing Attachments with Custom Multivariable Thickness

One of the most transformative capabilities of direct print is customized multivariable thickness. LuxCreo’s 4D Aligner™ technology allows us to vary aligner thickness across the appliance in a single print, optimizing force in targeted areas—without relying on composite attachments in some movements.

For doctors and patients alike, that’s a win:

• Fewer attachments = better aesthetics

• Less chair time = more efficient workflow

• Smart force application = more predictable movement

By controlling force through precise material distribution—not bonded hardware—LuxCreo’s aligners are able to deliver powerful, consistent tooth movement while preserving the patient’s natural smile during treatment.

This design precision isn’t just theoretical; it’s backed by real-world clinical performance. Providers report smoother tracking, fewer refinements, and significantly improved patient satisfaction.

Direct-Printed Bite Turbos: Built-In Correction

Bite turbos have traditionally required separate material additions or bonding. Now, they can be designed and integrated into the aligner itself with pinpoint accuracy. LuxCreo’s design tools allow for fully customized bite turbos to be integrated directly into the aligner’s anatomy.

Doctors can use these for:

• Anterior or posterior cross bite correction

• Deep bite correction

Because these are designed digitally and printed directly, there’s no risk of incorrect placement, dislodgement, or uneven pressure. The turbo becomes part of the aligner—streamlined, stable, and reliable.

Solid Pontics: Stability You Can Count On

When a patient is missing a tooth, aesthetics matter—but so does functional durability. Traditional pontics in aligners are often hollow or filled with composite chairside. The result? Aesthetic compromises, fragility, and extra steps for the provider.

With LuxCreo’s direct print process, solid pontics are fully printed into the aligner, offering:

• More realistic look and feel

• Structural integrity for eating and speaking

• Better support for adjacent teeth and movement

Because these are designed digitally and printed directly, there’s no risk of incorrect placement, dislodgement, or uneven pressure. The turbo becomes part of the aligner—streamlined, stable, and reliable.

Hollow Aligner Indications: Comfort Meets Control

Need eruption guidance or targeted occlusal relief? LuxCreo’s advanced design capabilities support custom hollow aligner zones that fit specific anatomical or treatment needs.

We’ve affectionately nicknamed them “Batman” and “Rabbit”.

These are clinically valuable but previously impossible to manufacture at scale using thermoforming. LuxCreo’s 3D print technology makes these designs accurate, repeatable, and fast to produce.

And because they’re completely digital, you can easily modify, scale, or replicate the designs for any patient need.

Why This Matters

Direct print aligners aren’t just a new material—they represent a fundamentally better design philosophy. LuxCreo’s workflow makes these features possible at scale, without adding complexity to the provider.

These enhancements—multivariable thickness, integrated turbos, solid pontics, and hollow zones—are not just gimmicks. They’re the future of aligner treatment, driven by better biomechanics, better comfort, and better outcomes.