Comparing 3D-Printed Versus Thermoformed Clear Aligners for Orthodontic Treatment in Young Adults

What this Trial Is About

Researchers are evaluating the clinical effectiveness of two types of clear orthodontic aligners for young adults aged 15 to 30 with mild dental crowding or spacing and fully erupted permanent teeth. The study compares in-office directly 3D-printed shape-memory aligners using Senertek Clear-A V2 resin to conventional multilayer thermoformed aligners made with Zendura FLX sheets. The main goal is to find out if the direct-printed aligners provide better clinical outcomes and patient satisfaction. Participants will be randomly assigned to one of two groups the experimental group receives direct-printed aligners fabricated via 3D printing, while the control group receives thermoformed aligners made by vacuum-forming over 3D-printed molds. Both groups will wear their assigned aligners for at least 22 hours daily, changing them every 7 days. The study will last between 6 and 12 months and involves multiple follow-up visits every 5 weeks. During the study, participants will undergo initial digital scans, photos, and panoramic X-rays for treatment planning. Digital models will be compared before and after treatment to measure how accurately tooth movements match the planned movements using 3D superimposition techniques. Researchers will also evaluate clinical efficiency, patient-reported discomfort, manufacturing complexity, and aligner properties like shape memory and color stability throughout the treatment period.

Clinical Performance of Direct-Printed Versus Thermoformed Aligners