Guide for Thermoforming Clear Appliances With 3D Printed Models

By producing thermoformed clear aligners and retainers, practices and labs can offer an invaluable service to patients and clients, all while saving time and reducing costs. This application guide provides a comprehensive walkthrough of the clear aligner and retainer workflow.

Required Hardware

• Shape X RP
• Shape X 3D Printer
• Shape X Wash/Dry
• Shape X Cure

• 3rd Party Dental Lab scanner for dental models or impression.
• 3rd Party Intraoral scanner for direct patient scan.

Required Software

• Shape X CAM

• 3rd Party Dental CAD software for designing restoration.

Required Materials

• Shape X Model Resin.

• Isopropyl alcohol (IPA) ≥99% .
• Thermoforming machine
• Plastic film suitable for machine and appliance
• Cutting & Trimming tools

In order to design a dental prosthetic using dental CAD software, it is necessary to obtain a digital representation of the patient's anatomy. This can be accomplished by either directly scanning the patient's mouth using a 3D intraoral scanner or by scanning a physical impression or poured model using a desktop 3D scanner.

The landscape of orthodontic and model software is evolving at a rapid pace, offering a wide array of options to choose from. We strongly advise conducting thorough research on the different software options available to determine the most suitable choice for your dental laboratory or practice. It is crucial to find a software solution that aligns with your specific needs and requirements.

To reduce printing costs, we recommend using a hollow dental model with a minimum wall thickness of 2.5mm. It is advisable to incorporate multiple vent holes, each with a diameter ranging from 3 to 4mm. These vent holes help prevent the formation of suction cups that can lead to failed prints.

Most dental design software typically generates a manufacturing file in the .stl format. To proceed, you need to find this file and transfer it to Shape X 3D Printer.

* Before Press "Print" button:

> Please ensure that the black screw of the build platform and the set of two screws that hold the resin container are securely tightened.

> Carefully inspect both the build platform and the resin container film to ensure there is no cured resin present.

> Ensure that the resin temperature falls within the recommended range of 25 to 35°C. Preheat the resin if necessary and mix it thoroughly with Shape X RP. Before use, clean the resin container with a filtration paper if it has been previously used. Additionally, ensure that the resin is not expired and that the quantity in the container is above the indicated minimum level.

4.1 Part Removal

To remove the printed parts from the build platform, utilize a scraping tool positioned beneath the part raft. By rotating the tool, gently separate the parts from the platform.

4.2 Washing

In a well-ventilated area and while wearing appropriate protective masks and gloves, submerge the printed parts in an isopropyl alcohol (IPA, ≥99%) solution within the Shape X Wash/Dry apparatus. Allow the parts to undergo a 3-minute washing cycle.

or submerge the printed parts in an isopropyl alcohol (IPA, ≥99%) solution within a black box. Allow the parts to undergo a 6-minute washing cycle.

4.2 Drying

Utilize compressed air to aid in the drying process of the parts, facilitating a quick inspection of unwashed resin remaining after using Shape X Wash/Dry machine.

4.3 Curing

While keeping the raft and supports intact, position the printed parts in the Shape X Cure device with the raft side facing downwards. Proceed to post-cure the parts for a duration of 2 minutes.

4.4 Thermoforming

> Incomplete washing and UV curing of models can cause the thermoforming material to adhere to them.

> Unwashed resin will have a shiny appearance and feel tacky to the touch.



To address this, we suggest utilizing pressure formers that exert positive pressure to push the material over the model. Some pressure formers worth considering are Dentsply Drufomat, Great Lakes MiniSTAR, and Erkodent. These options can help ensure proper forming without the risk of material sticking to the model.

Begin by separating the model from the plastic sheet. Next, carefully trim the appliance to meet the necessary specifications or requirements.