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Next-Generation Orthodontics: Functional Resins, Biomechanics, Biocompatibility, and Current Clinical Reality of Direct 3D-Printed Aligners
Summary
Scientists reviewed new 3D-printed teeth straighteners that could replace traditional clear aligners, potentially offering better fit and even delivering antibacterial treatments or fluoride directly to teeth. However, early research shows these newer aligners may release harmful chemicals and create microplastics in the mouth. More long-term safety studies are needed before these 3D-printed aligners can be considered safe alternatives to current teeth straightening methods.
The orthodontic landscape is currently witnessing a significant technological evolution with the emergence of direct 3D-printed aligners (DPAs), which promise to close the digital workflow loop by eliminating the geometric limitations and solid model waste inherent to traditional thermoformed clear aligners (TCAs). This review provides a comprehensive analysis of the material science governing this transition from inert thermoplastic sheets to reactive photocurable resins. We explore the fundamental chemistry of DPA materials, and the pivotal role of post-processing in ensuring mechanical integrity and biocompatibility. Beyond passive mechanics, this review highlights preclinical research in functional material engineering, detailing how experimental DPAs are being investigated for the integration of antibacterial agents, remineralization fillers, and drug delivery systems. Furthermore, we evaluate the limited but emerging clinical data on DPAs, contrasting their shape-memory properties and force delivery profiles with conventional appliances, while critically addressing emerging safety concerns regarding monomer elution and microplastic generation. We conclude that while DPA technology offers superior dimensional control, comprehensive life cycle assessments and long-term in vivo trials are essential to fully substantiate their clinical efficacy, overall sustainability, and potential as advanced orthodontic appliances.