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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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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!

Abby L.
they were so so kind and amazing and very helpful!!
Adriane H.
Today I officially graduated from wearing my retainers. I had a wonderful journey with the whole team. I laughed and had a great time with all the ladies and Dr Stoner. They made me feel comfortable each visit. And I walked away with a beautiful smile!. Thank you to the whole staff for being so awesome!.
Jallon T.
My second time getting braces here and it went amazing! Thank you ! For making my smile perfect again
Emily F.
Working with Dr Stoner and his staff has been a wonderful experience.
The staff has been so kind and so well organized. Dr Stoner was great to explain each process and the outcome of treatment is what we hoped for and more!
Would recommend to anyone anytime to come here!!!
Andrea M.
Very professional and kind. Made my invisalign journey easy.
Valencia H.
I had such a great experience! The entire team is awesome and so happy with my new smile!
Samuel C.
Very nice and supportive people very glad I got my braces done here never felt better
Amber C.
I absolutely love this place. The staff is amazing. Shout out to Leslee for taking care of me, and Lindsey for keeping up with the progress! I came into the office to get my teeth straighter and to loose my gap and Stoner and his team has not disappointed at all. Highly recommend
Amy Q.
We have been at this practice for 10 years with four children. I couldn't imagine being anywhere else for our family's orthodontic treatment. The staff is phenomenal and the care is second to none!! Our smiles say it all!
Iris M.
Dr. Stoner and his associates are the best. I came in with teeth spreaded out in all directions. I’m happy to say they are now all perfect and straight. They are the best and I’m truly happy and grateful!
Amie C.
Great experience - the entire team is a friendly, helpful. They are easy to work with and have made this experience exceptional.
Latoria Robinson (.
They are so nice in the office. They are very helpful with helping you understand everything they have to do and it’s no rush with the work. I would tell anyone and everyone to go. My teeth looks so great until it makes me want to cry. I just love smiling now and will continue to do so. Anyone that’s need dental work on their teeth. I will say go see them as soon as possible
Brittany G.
Stoner Orthodontics has been amazing for our daughter’s aligners' journey. The staff is kind, professional, and very welcoming. Dr. Stoner explained everything clearly and made the process easy. Our daughter’s smile looks fantastic—we’re so happy with the results!
Chantay P.
I am very pleased with the staff and the services provided for the past two years my teeth look amazing and I’m very grateful to this practice for all they’ve done to help me
Lauren B.
I have had an awesome experience with Dr. Stoner and his staff! Highly recommend!
Kaelin B.
Very sweet people !! Answer every question I asked and made sure I understood everything!!
Carly M.
We have loved our experience! I would highly recommend!
Delaiah C.
110% would recommend Dr. Stoner and team!! They made a long invisalign process so much less stressful by being open communicators and always super friendly.
Ashleigh F.
Whew! Where do I start?! First of all Dr Stoner is AMAZING!! So friendly so personable and professional. I was in bad shape when I came in 2023 and him and his entire team took care of me from the beginning. I just finished my Angel Aligner treatment and I’m completely speechless. Moved to Vegas and they still made sure my treatment was flawless!! He’s a true perfectionist so just trust the process. I love my smile so much and truly recommend if you want top tier orthodontic treatment. Ashley Lindsay Ali Leslee Meredith omg I can’t name you all! From front desk to treatment floor I cannot thank you all enough. Fighting tears as I type this❤️
Amy L.
We love Robert Stoner Ortho and all of his staff. All of our children have beautiful smiles thanks to them!
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