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3D Printing’s Role in Modern Braces & Aligners

Making Smiles Inside & Out

A Mouth-to-Mouth Comparison
  • Robert Stoner Orthodontics
  • June 17, 2025

Orthodontics has evolved significantly over the years, with new technologies making treatment faster, more precise, and more comfortable. One of the most groundbreaking advancements is 3D printing, which is transforming the way braces and aligners are designed and manufactured.

At Robert Stoner Orthodontics, we embrace the latest innovations to provide our patients with high-quality, customized care. Here’s how 3D printing is shaping the future of orthodontics and improving patient experiences.

How 3D Printing is Used in Orthodontics

3D printing, also known as additive manufacturing, allows orthodontists to create customized appliances with an unprecedented level of accuracy. Instead of relying on traditional molds and laboratory fabrication, orthodontists can now use digital scans and 3D printing technology to create highly precise models of a patient’s teeth.

This technology is used to produce:

  • Clear aligners, such as Invisalign and other in-house brands
  • Custom braces brackets tailored to each patient’s tooth structure
  • Retainers that fit more precisely and last longer
  • Orthodontic models used for treatment planning and adjustments

Because 3D printing can replicate fine details with exceptional precision, it allows for more predictable and effective orthodontic treatment.

Benefits of 3D Printing in Braces and Aligners

More Precise and Efficient Clear Aligners

Clear aligners have become one of the most popular orthodontic treatments, and 3D printing plays a significant role in their production.

With digital scanning, orthodontists can create a highly accurate virtual model of a patient’s teeth. This model is then used to print a series of aligners that gradually shift the teeth into their ideal positions. Since 3D printing allows for fine adjustments at each stage, the treatment process is both more comfortable and more effective for patients.

The use of 3D printing also eliminates the need for traditional impressions, making the process faster and more convenient. Patients no longer have to experience the discomfort of bite molds, as digital scanning captures a perfect representation of their teeth in seconds.

Customized Brackets for Braces

For patients who require traditional braces, 3D printing has improved the design and application of brackets. Instead of using standard, one-size-fits-all brackets, orthodontists can now create custom brackets that fit each tooth perfectly. This ensures better bonding, improved comfort, and more efficient movement of the teeth.

Orthodontists also use 3D-printed indirect bonding trays, which allow multiple brackets to be placed at once. This reduces the amount of time spent in the orthodontic chair and ensures precise placement for optimal results.

Faster and More Accurate Retainers

After completing orthodontic treatment, patients need to wear retainers to maintain their results. 3D printing allows for the quick and accurate production of retainers, ensuring a perfect fit.

If a patient loses or damages their retainer, the digital scan remains on file, making it easy to print a replacement without the need for another impression. This helps patients keep their teeth aligned without interruption.

Reduced Costs and Environmental Impact

3D printing has made orthodontic treatment more cost-effective and environmentally friendly. Because 3D-printed appliances require fewer materials and less manual labor, they reduce production costs, which can make treatment more affordable for patients.

Additionally, traditional mold-making techniques generate more waste, while 3D printing uses only the necessary amount of material, making it a more sustainable option.

The Future of 3D Printing in Orthodontics

The role of 3D printing in orthodontics continues to grow, with future developments likely to bring even greater advancements. Researchers are exploring the potential for directly 3D-printed clear aligners, which would eliminate the need for traditional thermoforming methods. Other innovations, such as biocompatible materials and smart orthodontic appliances, may further improve the patient experience.

At Robert Stoner Orthodontics, we are committed to staying at the forefront of these advancements, ensuring our patients benefit from the latest technology in orthodontic care.

Experience the Benefits of 3D-Printed Orthodontics

3D printing has made braces and aligners more precise, efficient, and comfortable than ever before. Whether you are considering clear aligners, braces, or retainers, modern technology ensures that your treatment is tailored to your individual needs.

If you are ready to start your orthodontic journey with the latest innovations in treatment, schedule a consultation with Robert Stoner Orthodontics today.

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Our 5-Star Experience

We are passionate about serving our patients with the highest level of care possible. Check out what our patients are saying about their 5-star experience with us!

Elizabeth S.
The whole experience with getting liners for my teeth, ending up being easier than I thought it would be. The office is such a lovely, positive and happy place to be in. I have to wear these liners for two years. In the beginning, I thought it would be horrible and it turned around to be Not so bad after all. I would highly recommend them
Wally H.
Great work. Friendly staff. They treat you like family!
TYISHA CHAPMAN MA C.
I wish that I could give at least 5 more stars. Everyone here has been caring and professional. My teeth are healthier. My smile looks amazing and my confidence is on clouds.
Chrissy D.
We have been with Stoner orthodontics for years. We have had wonderful experiences with Dr. Stoner as well as his staff. They have been very attentive to our needs. We quickly get into our appointments and they were right on track with the timeline of braces.
Asli S.
Friendly, professional, great service! Highly recommend!
Jeff and Allison T.
Leslee and Ashley give exceptional care and I would recommend anyone to go to their practice.
Jeremy D.
We have been going here for years for our four children and appreciate the compassionate, quality care we have received. Amazing customer service. The staff goes above and beyond to help. Would highly recommend!
ahmedta V.
Dr. Stoner and his wonderful staff have become almost like family. They very professional yet warm and fuzzy. And I love that for myself 😉❣️
Angel P.
Been going for years and they've always done an amazing job. Recently has done my Aligners and my teeth have never looked better.
Lakeisha W.
A Huge THANk YOU To Dr. Stoner and Staff !! My Daughter Autumn has loved going to Robert Stoner Orthodontics since day one!! Always on time getting her started for her appointments , very detailed with instructions how to take care of her teeth, and of course extremely kind and always smiling with great positive energy welcoming her into every appointment:) Today was the day to get her Braces taken off and Dr. Robert Stoner took out the time to take a before and after picture with her. Thank you Doc :) The small things means So Much !! Also a Shout out to the dental assistant Kaitlin who went thoroughly in detail how to use and take care of her new retainers and also making sure that it properly fits her mouth :) Again THANK YOU, THANK YOU Stoner Orthopedics , you’ve made her Experience nothing but AMAZING , most of all thank you for her Beautiful Smile :)
Clint S.
Amazing service, professionalism, and my wife says my smile is perfect! Thank you all!
bianca M.
We have loved and enjoyed our experience with Robert Stoner orthodontist team. Would highly recommend to others.
hilary W.
Excellent care and great results. Highly recommend for your entire family.
Sona H.
Wonderful experience for both my girls with Invisalign! Amazing office staff at both locations. Highly recommend coming here for your orthodontic needs!
Dan J.
Made my teeth very straight and fast !!! 100% recommend
Brenna P.
Fantastic experience!! We love everyone here and I highly recommend!!
Millie S.
Both my fiancé and myself have been patients here for years and will say that everytime has been amazing. We've done Invisalign and Angel Aligners. Great customer service, friendly staff, and Dr. Stoner is always willing to answer any questions, comments, or concerns.
Kelissia H.
Very satisfied with my treatment at Robert Stoner Orthodontics. Everyone is so welcoming and tends to patients needs very well. I will definitely recommend this place to anyone looking for a great orthodontist.
Aida R.
My daughter just removed her braces and we are very pleased with the entire process. The staff is always very friendly and courteous.
Kate S.
Great experience all the way through. Dr. Stoner and staff are knowledgeable, friendly and helpful!
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