Clinical Case Study

Validating 3D Printed Direct Bonded Orthodontic Appliances

Planning, Bonding, and the First Five Months of Treatment: In this clinical case study, a phased hybrid orthodontic treatment plan is documented.

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  • Introduction
  • History and Clinical Examination
  • Treatment Plan
  • Fabrication of Fixed Appliances Prior to Same Day Start
  • First Appointment: Initial Bonding of Upper Fixed Appliances
  • Second Appointment: 2 Months of Progress
  • Third Appointment: 3 Months of Progress and Bonding of Lower Appliances
  • Fourth Appointment: 5 Months of Progress and Adding a Reverse Curve Lower Archwire
  • Clinical Considerations with Esthetic Brackets
  • Conclusion


Advances in digital case planning, design, and 3D printing continue to transform orthodontic practice. In 2020, Braces On Demand introduced a 510(K)-cleared platform for clinicians to design, order, and even fabricate their own brackets and other direct bonded appliances in-office. Using advanced biocompatible materials and 3D printing, they introduced a solution for ondemand manufacturing of orthodontic appliances.
To see these advanced concepts in action, a clinical case was carried out. The focus consists of a phased orthodontic hybrid treatment:
  • Phase I - Fixed orthodontic treatment via 3D printed brackets designed and ordered through the Braces On Demand platform and printed with the Form 3B and Denture Teeth Resin.
  • Phase II - Clear aligner treatment produced by thermoformed sheets upon 3D printed models that were fabricated with the Form 3B and Draft Resin. A final retainer will be produced at the end of the treatment via this technique as well.

History and Clinical Examination

A healthy 12 year, 11 month old female patient presented for a consultation with the chief complaint: “Please align my crooked top right tooth and also fix my overbite.” The patient presented with a missing LR2, buccally impacted UR3, canted maxilla, and moderate upper and mild lower crowding. She also has an excessive curve of Spee and curve of Wilson. This patient also had no nasal breathing or sleep concerns.

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