Since its inception, Align has partnered with 3D Systems to create highly customised additive manufacturing components – the company produces up to 320,000 unique medical devices (Invisalign clear aligners) per day. Align has harnessed the accuracy and scalability of 3D printing to grow its patient base nearly six times since 2009, with more than 5.8 million patients treated globally.
“Align Technology disrupted the orthodontic industry by creating a digital approach to straightening teeth that makes treatment possible for more people than ever,” says Srini Kaza, vice president, product innovation, Align Technology. “None of what we have been able to achieve would be possible without 3D printing technology. We are leveraging our mass customisation capabilities, including 3D printing, as we expand manufacturing operations in China – Align’s fastest growing region.”
3D Systems partnered with Align to develop a customised solution that meets Align’s long-term business strategy and goals using 3D Systems’ ProX SLA 3D printing technology, materials and software as part of its aligner fabrication workflow. The additive manufacturing solution is used to create sacrificial tooling, which leads to the creation of the final, patient-ready aligners.
One of the benefits of 3D printing is the ability to print many different parts at once, with each print run potentially including aligners for multiple patients. To avoid confusion, each aligner has a unique patient ID which is added into its design through the CAD file and printed directly into the device. This unique identifier does not divulge any patient information, yet allows manufacturing technicians to track and manage production and shipment of each patient’s complete set of aligners.
