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Clear Aligners Automated Production Workflow Guide

Scanning and Data Acquisition

It all starts with precise data. RayForm’s digital workflow is compatible with all major intraoral scanners (such as 3Shape, iTero, and Medit). We support direct import of STL/PLY format files, ensuring the instant transmission of patient dental data.

  • Open Data Ecosystem
  • High-Precision Mesh Restoration
Treatment Planning

Using AI-assisted orthodontic design software, a series of progressively corrective dental model data is generated. The RayForm team can assist in connecting with professional design centers to generate 20-50 step movement plans based on the doctor’s prescription.

Treatment Planning
Automatic layout and preprocessing

To maximize mass production efficiency, we offer intelligent nesting software. With a single click, it automatically lays out or stacks hundreds of dental model data from dozens of patients onto the printing platform and automatically adds tagging to prevent production confusion.

High-speed 3D printing mass production

This is the core of the process. It uses RayForm Ortho Model Resin in conjunction with an HADP™ array printer.

  • Ortho Model Resin is specifically designed for vacuum lamination, featuring extremely high temperature resistance (High HDT) and surface hardness to ensure no deformation during lamination.
  • High throughput: Full-page printing takes only 20-30 minutes, with a single machine capable of producing 500+ dental models per day.
Automated Washing

After printing, use isopropyl alcohol (IPA) or alcohol to remove any residual resin from the surface. RayForm provides SOP cleaning parameters and recommends a two-stage cleaning process of “coarse cleaning + fine cleaning” to ensure that the model surface is free of stickiness and to guarantee the transparency of the final dental crown.

Post-curing (UV)

The resin is irradiated with ultraviolet light at a specific wavelength (405nm) and temperature (60°C) to achieve its maximum mechanical strength. This step is crucial to ensure that the model does not collapse or deform during the subsequent high-temperature lamination process.

Thermoforming

The transparent membrane (TPU/PETG) is softened by heating and then tightly bonded to the cured 3D printed dental mold under vacuum and high pressure. RayForm modeling resin’s excellent breathability and surface detail ensure precise membrane molding and comfortable wear.

Cutting, Polishing and Delivery

The final step involves cutting away any excess membrane along the gum line (using laser cutting or CNC milling) and polishing the edges. After rigorous quality control, the aligners are cleaned, sterilized, and packaged, completing a high-quality clear aligner.

Ready to establish your invisible orthodontic production line?
Whether you’re building a new lab or expanding production capacity, RayForm’s team of application engineers can help you plan a complete solution, from hardware selection to process training.

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