ClearCorrect Expands Dental Production Facility with Stratasys PolyJet
3D Printing Case Study – Dental

ClearCorrect LLC, a leading manufacturer of clear orthodontic aligners, has added more Objet Eden500V 3D Printers to its sizable fleet of Stratasys 3D Printers. With this addition, ClearCorrect will realize a 30 percent increase in its capacity to produce custom-made orthodontic aligners since all aligner models are now being 3D printed.

The completely clear dental aligners allow for a more natural smile throughout treatment. The aligners are more comfortable than their metal counterparts, and the plastic material used is compatible with individuals who are sensitive or allergic to metal components.

A Clear Orthodontic Advantage

ClearCorrect’s orthodontic aligners are a major improvement over the metal braces traditionally used to straighten teeth. The ability to remove the aligners allows patients to eat foods that were a problem with traditional braces, and ensures easy access for brushing and flossing. 

“Initially, we started with just a few Stratasys 3D printers, and we have quickly transitioned to full production, where 100 percent of our models are now 3D printed,” said Jarrett Pumphrey, CEO of ClearCorrect. “We’re growing fast and adding more Stratasys 3D Printers to our digital workflow means that we can easily scale up with demand—enabling us to service more orthodontists with faster delivery times.”

With the use of the Objet Eden500V 3D Printer, the company can quickly print 3D models throughout each step of a patient’s orthodontic treatment.  The process begins with a digitized scan of a patient’s mouth. 

This scan is used to create accurate 3D printed models in Stratasys’ VeroDent material, which are then thermoformed with a specially formulated plastic to create custom, clear aligners. 

When worn, the aligners will apply pressure to the patient’s teeth that need to be moved. Every two to three weeks, the patient will begin wearing a new set of aligners to continue the realignment process until treatment is complete. 

Individualized Patient Treatment on a Mass Scale

ClearCorrect’s additional Stratasys 3D Printers will benefit their customers by further shortening the company’s lead times and accommodating rush orders. ClearCorrect's previous investment in the Objet series of 3D Printers has been realized several times over with optimized workflows, faster production, and delivery of individualized clear aligners on a mass scale – all at a lower cost per case.

”The versatility of the Objet Eden500V 3D Printers gives ClearCorrect the ability to efficiently manufacture high quality aligners on a mass scale, expand in existing markets, and enter new markets. The decision to expand their 3D printing operation demonstrates how Stratasys has earned ClearCorrect’s trust through reliable performance and customer support,” said Avi Cohen, Director of Global Dental at Stratasys

”The 3D printers alone are not the only reason for working with Stratasys,” added Pumphrey. “Stratasys really stands behind their 3D printers, and we are extremely happy with the dedicated support we receive from their technicians and customer support team.”