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.

  • 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
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.

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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Digital Workflow: 3D Print Clear Aligner Models

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.
Download 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 Gray

High accuracy and speed for models of all types

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Read IFU
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 and speed
  • Rich color and smooth surface texture
  • Excellent strength and dimensional stability


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

SprintRay Die and Model Gray
70.1 MPa
Sprintray Model Gray
48.8 MPa


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

SprintRay Die and Model Gray
1.8 GPa
Apply Lab Work Gray
1.0 GPa
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 Post-processing
3D Printing Materials
3D Printing Software