Adaptive Multimaterial Orthodontic Aligners via Dual-Wavelength 3D Printing (AMOA3D)

Programme

KLWPT 24/26, KLWPT 24/26, Kreislaufwirtschaft und Produktionstechnologien 2024

Project coordination

Montanuniversität Leoben

Project partners

• Danube Private University
• Polymer Competence Center Leoben GmbH
• Luxinergy GmbH

Researchers involved at DPU

• Univ.-Prof. Dr. Constantin von See, MaHM MSc
• Univ.-Prof. Dipl.-Ing. Dr. techn. Christoph Kleber
• Ass. Prof. Dr. med. dent. Michael Moncher

Abstract

Many adult patients find fixed braces to be aesthetically unpleasant and therefore prefer treatment with orthodontic aligners for reasons of comfort. The aligners are transparent, so they are barely noticeable, and because they are removable, oral hygiene is significantly improved. In general, these splints can be used to move teeth and correct mild to moderate misalignments. They are either made by hand by a dental technician or industrially by commercial providers.
In recent years, attempts have been made to produce dental splints directly using DLP-based stereolithography, which can eliminate time-consuming process steps and save expensive materials. However, significant disadvantages of this concept are that I. lower forces can be exerted on the teeth than with conventionally manufactured aligners and II. the stress relaxation in the splint occurs very quickly. Both have a negative effect on the duration and success of treatment and make the correction of severe misalignments technically impossible.
The approach pursued in the AMOA3D project enables the realisation of multilayer systems that allow for aligner architectures with higher toughness and lower creep and stress retention. By creating locally stiffer areas and implementing soft active functionalities, the force on the misaligned tooth can be increased. The successful completion of the project will lay the foundation for a process (TRL4) that enables the cost-effective and economical production of aligners and allows complex misalignments to be treated efficiently.
Tooth misalignments are common among the population and can not only affect quality of life but also lead to medical problems. Due to the aesthetic and medical disadvantages of fixed braces, orthodontists are increasingly using transparent aligners. Splint therapy is one of the fastest developing areas in orthodontics. The global market is expected to grow at an annual rate of 25.2% between 2024 and 2032.
The AMOA3D project will make a significant contribution to the sustainability goals. The use of stereolithography significantly reduces waste compared to conventional manufacturing processes. Additive manufacturing uses only the material needed for the product, reducing the ecological footprint. A focus is on developing sustainable photopolymer resins that have a lower environmental impact, including options for recycling and biodegradation. By reducing the time and cost of orthodontic treatment, this project makes advanced dental treatments more accessible and affordable to a wider range of people, thus contributing to both social and economic sustainability.

Read more about the project