3D Print Clear Aligner Models

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

Digital Workflow
Pro 3D Printer

Offer clear aligners in-office 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. Though you will not directly 3D print clear aligners themselves, this process significantly reduces lead times.

Key Benefits

  • 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

Calculate ROI
3D Print Clear Aligners

Clear Retainers (Essix)

Clear retainers are a common post-treatment appliance that is frequently lost or broken. Provide outstanding patient benefit by creating a replacement same- or next-day for only a few dollars in materials cost. Similar to the method used to 3D print aligners, this can provide an outstanding benefit to your patient with minimal additional cost.

Import your raw intraoral scan into RayWare Pro and make it printable with the click of a button. Use SprintRay Pro to fabricate the model in less than 30 minutes, then post-process. Thermoform over the printed model and trim, then deliver to your patient.

View Workflow Guide
3D Print Clear Aligners

Digital Bracket Removal

Deliver patient delight and reduce followup appointments by having a retainer premade for every bracket removal appointment. Provide a scan of the patient’s dentition with braces, and our team will digitally remove them, providing you with a model that you can print and use to thermoform a clear retainer.

Learn About Bracket Removal
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.

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Return on Investment

3D printing models for aligner production allows you to deliver treatment faster while saving big on lab bills. 
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Variables and Costs for 3D Printing Clear Aligners In-office

Return on Investment When Using 3D Printing

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Profit Up To

$ 3,135.46

Per Case

When 3D printing even just a few cases of aligners per month, mosts clinics break even on their investment after just one or two months compared to traditional big-box lab bills. Printing can help offices maximize their income streams and multiply investments in other digital technologies such as intraoral scanning. SprintRay Pro is capable of fabricating a wide array of appliances other than aligners, making it a highly versatile tool for almost every dental office.

In-office manufacturing costs listed include monthly equipment cost and digital design fee if applicable. Labor, materials, and consumables costs are not listed in this calculator. This calculator is for demonstrative purposes only. Actual experience may vary.

Digital Workflow Explained

3D Printing Models for Clear Aligners

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.
View Workflow Guide


Our large library of dental printing materials are designed to get the most out of SprintRay 3D printers. Whether you're using resins from SprintRay or one of our growing list of materials partners, you’ll receive highly-accurate, outstanding results thanks to our extensive validation process.

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See Open Certified Materials

SprintRay Die and Model 2 Gray

Rapidly 3D Print Models for Aligner Production

Read IFU

  • Improved flexural modulus and strength
  • Up to 10% faster print speeds
  • Print up to eight full arch models in just 15 minutes*
  • High-contrast color for maximum visibility of small details
  • Easy to separate from thermoforming materials


SprintRay Die & Model 2 represents a big step forward in dental modelling materials. Our new gray color offers extremely high color contrast to help illustrate details. This new resin features almost no pigment settling, which means you can spend more time printing and less time mixing. Improved adhesion to the build plate is matched by an increase in flexural modulus and strength, providing higher success rates and a reduced chance of breakage.

A reduced odor improves the quality of life for 3D printing models for an overall experience that your practice staff will love. Die & Model 2 Gray features an improved color tone, making it easier than ever to use digital technology to perform advanced restorative dentistry. With rapid, repeatable results that are easier than ever to use, Die & Model 2 Gray is helping to bring dental 3D printing into dental practices everywhere.

* When printed on SprintRay Pro with Ludicrous Speed profile. Learn More


Higher flexural modulus prevents the model from distorting, which can impact accuracy.

Die and Model 2 Gray
2650 MPa
Die and Model Tan
1700 MPa


Higher flexural strength ensures that the model doesn't break during normal use.

Die and Model 2 Gray
91.5 MPa
Die and Model Gray
66.7 MPa
SprintRay Pro 3D Printer

More Accurate than Stone

A recent university study found SprintRay Pro more accurate and consistent than traditional alginate methods. With an average RMS of 129±16μm for 3D printing compared to 177±25μm for alginate methods, SprintRay Pro is ready to meet the clinical demands of contemporary dentistry

Read About Accuracy
About SprintRay Pro
SprintRay vs Others

Dental 3D Printing Control Center

RayWare is the 3D printing software that’s designed specifically for dental professionals. It’s easy to learn, and our California-based support team is just a phone call away. In addition to nesting printable files, RayWare allows you to fix, close, and base raw intraoral scans from any scanner with a click of a button.
Test Drive RayWare

Compatible 3D Scanners

You can use any scanner type you’d like with RayWare. 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

RayWare allows you to choose a dental design software that meets your clinical needs. This list shows our recommended options, but RayWare 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

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.

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Desktop 3D Printer
Automated Wash/Dry
Automated Post-processing
3D Printing Materials
3D Printing Software