3D Printing Dental Clear Aligners

In-office fabrication of clear aligners using 3D printed models.


Offering clear aligners in-office allows you to give patients the treatment they want at a price they can afford. This application allows you to set your own fees and rapidly see a return on your investment due to the significant cost savings compared to aligner labs.

When used in conjunction with a thermoforming machine and orthodontic CAD software, full cases of aligners can be fabricated in a single day.

  • Produce 4 upper and 4 lower aligner trays with one batch of printed models
  • Produce bleaching trays at any stage of the orthodontic treatment plan
  • Significant cost savings compared to aligner vendor labs
Free Consultation
Practice Insights

Dr. Baron Grutter's In-Office Clear Aligners

Dr. Baron Grutter is an innovator in digital dentistry. His courses and videos offer step-by-step workflows and processes to help doctors integrate digital technologies into their practices. Read this SprintRay Practice Insight to see how using SprintRay 3D printers to fabricate in-office aligners help his practice.

Download Practice Insight

Workflow Overview

Download Workflow Guide

With 3D printing, you can have as much control over the process as you’d like. Use 3rd party software to plan the whole treatment plan yourself or use a service provider and simply perform a clincheck and approve. 

Images are courtesy of eXceed Ortho

3d cad/cam software planning

Design and Plan

Design the appliance using dental CAD software or use a digital lab and simply recieve printable files.

3d printing software

Print and Process

Prepare 3D models, print them, and post-process according to requirements.

3d printed appliance for aligners


Create aligners using thermoforming machine and remove excess material.

clear aligners for dentists


Deliver the appliance as recommended.

Compatible 3D Scanners

You can use any scanner type you’d like with SprintRay Software. We accept any .STL formatted scan data. This list of scanners shows many options that our customers often use, but it is not an exclusive list.
  • 3Shape – Desktop & IOS
  • Planmeca – IOS
  • Cerec – IOS
  • 3M – IOS
  • iTero – IOS
  • Medit – Desktop & IOS
  • Dental Wings – Desktop & IOS
  • Carestream – IOS
  • Shining 3D – Desktop & IOS
  • Condor – IOS
  • Heron – IOS
  • Open Technologies – Desktop

Compatible Design Software

SprintRay Software allows you to choose a dental design software that meets your clinical needs. This list shows our recommended options, but our software accepts any design file formatted in .STL, which means you can use whatever you’re most comfortable with.
  • 3Shape
  • BlueSkyBio
  • Exocad
  • Archform
  • Orthoselect
  • eXceed Ortho

Accuracy Information

SprintRay 3D printers have a global accuracy across a full arch within ±100 microns over 93 percent of the surfaces when printed at 50 micron layer thickness.

Applicable Materials

Our large selection of dental printing materials are designed to get the most out of SprintRay 3D printers. Developed and tested for market-leading performance, SprintRay resins are built to achieve equivalent or superior results while providing better value for money.


SprintRay Die and Model Gray

Rapid, accurate models for everyday use

Read IFU
Download SDS
SprintRay Die and Model Gray is designed for removable dies and models for orthodontic, study, and restorative applications. This all-new model formulation resists fracture and deformation, offering a streamlined 3D printing workflow while ensuring perfect fit for final appliances.
  • Outstanding accuracy
  • Rapid print speed for batch production
  • Excellent strength and resistance to distortion


SprintRay Die and Model Tan

High accuracy and rich color that mimics stone

Read IFU
Download SDS

SprintRay Die and Model Resin is designed for making accurate, removable dies and various models including orthodontic, study, and models for all restorative applications. The material’s color makes it easy to see fine detail, while its great accuracy allows for tight tolerances for removable parts.

  • Outstanding accuracy
  • Balanced color and rich surface texture
  • Excellent strength and resistance to distortion

Surgical Guides

Fabricate highly accurate, biocompatible, and FDA compliant guided surgery templates for dental applications.

Learn More

Dental Models

Fabricate restorative study models, removable dies, digital wax up models, and models for thermoforming clear aligners.

Learn More

Clear Aligners

In-office fabrication of clear aligners using 3D printed models.

Learn More

Digital Dentures

Interim dentures, delivered same day at a low cost. Denture try-ins to ensure final prosthetic fitments.

Learn More

Crowns and Bridges

Fabricate beautiful crowns with incredible detail.

Learn More

Indirect Bonding Trays

Fabricate flexible orthodontic appliances for speedy bracket placement.

Learn More

Provisionals and Wax-ups

Fabricate provisionals and wax-ups for restorative and cosmetic procedures.

Learn More


3D Print Dental Occlusal Guards and Splints in-office.

Learn More

Request a Sample Today

Order your free dental sample and learn how SprintRay 3D products can revolutionize your practice.
Request a Free Dental Sample

Cutting-edge Digital Dentistry Powered by SprintRay

The SprintRay 3D printing ecosystem is designed for the unique needs of dental professionals. With SprintRay as your partner, pushing the boundaries of what’s possible in dentistry has never been easier.

Schedule Consultation

Desktop 3D Printer
Automated Post-processing
3D Printing Materials
3D Printing Software