Introduction
The swift progress in 3D printing technology now produces remarkable changes to medical disciplines which includes orthodontics and dentofacial orthopedics. Through additive manufacturing methods which are commonly known as 3D printing the production of three-dimensional objects happens by advancing material layers according to digital designs. The service meets individual patient anatomical requirements which makes it essential for contemporary orthodontic and surgical interventions. The application of this technology in orthodontic care improves both treatment results and simplifies difficult processes which results in quicker and more reliable care. New developments in this technology now enable surgeons to use CAD/CAM systems for creating both standard orthodontic devices and advanced surgical instruments which has solidified their essential position in orthodontics and surgery research [1, 2].
3D printing provides orthodontics with an outstanding capability to design personalized dental appliances. Distribution of orthodontic appliances like aligners and retainers and braces becomes possible because 3D printing technology offers custom solutions based on individual dental structures. The customized fit improves comfort and increases treatment efficiency as one of its benefits. Virtually invisible teeth straightening products made using 3D printing technology have become the preferred choice for patients from different age groups because of their highly effective results. The application extends beyond orthodontic devices because 3D printing manufactures essential surgical guides needed for complex maxillofacial surgical procedures. The surgical guides help achieve both accurate surgery and minimally invasive treatment because they properly position surgical tools on precise anatomical landmarks which results in shorter healing periods and better patient satisfaction [3, 4].
3D printing technology benefits dental practice through its combination with digital workflow systems. Orthodontists benefit from CAD/CAM systems linked with intraoral scanners and 3D printers which enable them to generate precise devices [5]. Digital scanning transitions to physical appliances in a single process that decreases errors while shortening production times. This workflow system improves collaboration between orthodontists and maxillofacial surgeons and dental technicians which allows them to join forces for treating complex dentofacial abnormalities. Digital technology adoption enables better diagnosis to treatment connectivity for doctors because it produces more predictable and efficient clinical tools [6, 7].
The decisive advantages of 3D printing in orthodontics encounter specific implementation difficulties. The high expense of advanced 3D printers together with materials makes adoption difficult particularly for low-resource facilities. Long-term safety testing and performance research needs to be completed on some of the printed materials due to their durability and biocompatibility concerns [8]. Learning to implement 3D technology requires comprehensive education of both clinical staff and technical personnel. Implementation of cost-efficient innovations together with materials science progress and broad training programs will essentially enhance the accessibility and effectiveness of 3D printing in orthodontic practices worldwide [9, 10].
Future innovations in 3D printing technologies will provide unprecedented benefits for orthodontics and dentofacial orthopedics practice. Bioprinting represents an innovative process that creates biological tissues which shows potential for treating difficult maxillofacial defects. The application of artificial intelligence in multidimensional design and printing operations produces more exact and faster orthodontic procedures. Orthodontic treatment planning as well as execution will experience transformation through the accessibility of affordable technology thus launching a new standard of individualized dental care. This detailed introduction provides foundational knowledge to study clinical applications and advantages and obstacles as well as predicted developments of orthodontics and dentofacial orthopedics [11, 12].
This study explores 3D printing applications that serve orthodontic and maxillofacial surgery tasks through innovative device design approaches leading to enhanced treatment accuracy and patient comfort. This research will explore both the operational advantages together with speedier treatments as well as analyze the expenses of equipment and training needs for this technology. The research centers its focus on tracking forthcoming industry trends between bioprinting and artificial intelligence implementation for advancing creative approaches to critical subject knowledge.
The flowchart in Figure 1 shows the highest applications of 3D printing technology for orthodontics and maxillofacial surgery. This technology enables the manufacturing of customized dental products which include dental aligners as well as retainers alongside surgical devices that enhance surgical accuracy. Major benefits show better accuracy with improved patient comfort alongside limitations which include high expense for materials and equipment and requirements for training according to the diagram. The analysis examines prospective bioprinting technologies along with AI capabilities which aim to enhance medical device development potential for future expansion of the medical sector.
Background on 3D Printing Technology
3D printing technologies under the name of additive manufacturing have revolutionized numerous industries especially healthcare. Digital models guide the production of three-dimensional objects which get built layer-after-layer into finished products through a process that uses resins thermoplastics or biocompatible metals. Medical professionals use 3D printing to create exact dental appliances and instruments which help decrease mistakes and production periods. Treatment planning for specific patients becomes more efficient because 3D scanning now connects with CAD/CAM systems for digital-to-physical transitions. This digital method changes traditional manufacturing practices through delivery of enhanced modification choices as well as production speedups [1, 3].
The technology of 3D printing works with different materials which professionals can select based on their clinical needs. The production of orthodontic aligners uses biocompatible resins along with strong thermoplastics being used for retainers and surgical templates. The rising utilization of metal-based 3D printing methods now produces lasting orthodontic brackets and prostheses implants. 3D printing has become the essential framework technology in contemporary orthodontics because it enables clinicians to solve complex cases by delivering precise treatment for better patient results. Healthcare professionals continue to discover that declining printer and material costs will drive down expenses while making this technology more available worldwide. Additionally, research demonstrates this trend [6, 13].
Clinical Applications of 3D Printing in Orthodontics
Unprecedented clinical solutions emerged in orthodontics along with dentofacial orthopedics through the implementation of three-dimensional printing technology. The main use of 3D printing involves making orthodontic devices such as clear aligners and retainers and functional braces which are personalized for each patient. The devices achieve exceptional precision during design because it ensures each appliance fits the patient exactly for optimal comfort along with effective treatment results. Written dental scanner technology combined with three-dimensional printing enables healthcare providers to develop personalized dental adjusters from the unique patient structural features which produces better treatment results. The production time reduced by 3D printing techniques delivers precision results to patients and shortens their appliance acquisition times [2, 3].
Surgical guides built for complex dentofacial orthopedics serves as a major application field using these technologies. The surgical guides made through 3D printing serve as map-like structures which guide medical teams in their execution of accurate orthognathic procedures as well as implant surgeries. The surgical tools track with patient anatomy steadily through these guides to decrease surgical dangers and enhance treatment outcomes. Diagnostic models that stem from 3D printing help healthcare professionals evaluate difficult dental and skeletal relationships before deciding on treatment approaches for patients experiencing facial asymmetry or malocclusion. The models function both as important communication tools that enhance understanding of treatment procedures between patients and clinicians [11, 13].
Benefits of 3D printing in orthodontics
Orthodontic practice has transformed through 3D printing because this technology provides the field with precise customized treatment designs and delivery methods. 3D printing demonstrates its most crucial benefit through the generation of customized appliances which match individual dental anatomies of specific patients [14]. Listing individual patient dental features in the treatment planning process reduces discomfort whileboosting the effectiveness of orthodontic procedures. The production of 3D-printed clear aligners provides optimal alignment capabilities that make them deliver better treatment results when compared to traditional braces by shortening the overall treatment period. Orthodontic retainers and splints that emerge from 3D printing demonstrate enhanced precision and durability so they become the leading choice for practitioners as well as their clients [15, 16].
The central advantage of 3D printing technology includes the workflow streamlining and decreased production durations. Digital intraoral scans that link with CAD/CAM systems enable quick automatic data movement to 3D printers which decreases the time needed to design and fabricate orthodontic devices. The efficient workflow of this technology both speeds up treatment processes and minimizes production expenses thus delivering advantages to treating care providers and their patient base. The devices manufactured with 3D printing methods rely less on traditional molding and casting techniques that cause time loss and errors thus increasing product reliability [17, 18].
Three-dimensional printing enables healthcare providers to establish improved dialogue with their patients while also boosting treatment productivity. The precise 3D-printed models of patient oral anatomy help orthodontists show patients what their treatment plan and projected results will be [19]. The physical treatment models promote better patient education which improves both patient satisfaction and their treatment protocol adherence. Students along with professionals use 3D-printed models as essential tools for educational purposes and clinical case presentations because they allow detailed analysis of complex dental procedures [20, 21].
The innovation process finds support through 3D printing because it provides researchers with tools to explore both innovative designs and materials. The field of orthodontic science sees researchers dedicate their time to create new biocompatible materials for enhancing orthodontic devices through better strength and adaptable features and more pleasing characteristics [22]. Through the development of additive manufacturing orthodontists can test complex geometric shapes which were impossible to achieve through traditional methods. The technology produces superior care quality in addition to developing potential uses such as tissue bioprinting and regenerative orthodontic treatment possibilities [23, 24].
Challenges of 3D printing in orthodontics
The widespread spread of 3D printing technology in orthodontics remains restricted by several difficulties that prevent its general acceptance. The adoption of 3D printing in orthodontics finds its main obstacle in the high investment necessary for equipment and materials. Professional-grade 3D printers and their corresponding biocompatible materials necessary for orthodontic use remain out of reach for dental practices or clinics situated in restrictive resources environments because they cost an exorbitant amount of money. Routine orthodontic care fails to integrate 3D printing technology due to expensive maintenance requirements and ongoing equipment upgrades and their associated costs [25, 26].
3D-printed orthodontic appliances face two essential problems regarding their ability to withstand wear and their compatibility with body tissues. The ability of 3D printing to achieve complex designs does not guarantee durability in produced aligners and retainers or surgical guides to match standards of traditional orthodontics devices [27, 28]. A short lifespan of appliances due to wear-and-tear together with material breakdown combined with substandard mechanical properties required practitioners to replace their devices often which became an issue for both patients and dental professionals. Long-term safety evaluations need to be conducted for printed devices since they need to demonstrate appropriate tolerance with oral tissue conditions [29, 30].
The successful implementation of 3D printing systems requires expert training which needs immediate address. Learning and working with complex software modeling software and running advanced printers in addition to proper printing device post-production requirements make up the system. Orthodontists together with dental technicians struggle to adopt this technology because they need better skills and no access to training programs. Standardized education programs designed for dental experts need to be developed as a fundamental solution to remove this obstacle [31, 32].
Acceptance of 3D printing for orthodontics encounters multiple logistical obstacles that affect its use by dental professionals. The conversion process from traditional workflows into fully digital systems presents major challenges because it demands new purchases of intraoral scanners and CAD/CAM systems [33]. The digital workflow becomes less efficient when software and hardware does not work together because timing delays create operational problems that reduce quality standards. The challenge of implementing a full 3D printing setup throughout orthodontic clinics remains high since many practices lack the necessary infrastructure [34, 35].
The implementation of 3D printing technologies in dentistry requires resolution of ethical along with regulatory matters. The speed of technological progress exceeds current regulations so authorities have difficulty performing proper assessment of the safety quality of 3D-printed medical devices. Standards for all aspects of testing and approving as well as deploying these orthodontic devices need official implementation by regulatory bodies to protect patient safety and practitioner trust. Clear guidelines must be established to resolve intellectual property disputes about custom appliance design and printing because these issues may potentially develop [36, 37].
Future directions for 3D printing in orthodontics
The field of 3D printing in orthodontics and dentofacial orthopedics presents major opportunities to optimize patient care through upcoming technological innovations. Bioprinting stands out as one of the most thrilling potentials by developing capacity to produce tissue structures through compositions of cells and biomaterials. The technology of bioprinting shows potential for regenerative orthodontics because it enables repairs and replacements of harmed dental structures. Over time scientists have created 3D structures filled with stem cells to create new periodontal tissue which could aid in gum disease treatment. The manufacturing techniques involving 3D printers serve to unite these fields and establish this technology as an essential medical advancement [5, 9].
AI systems show great potential to enhance the current 3D printing operations. Operating on patient-specific information AI algorithms enhance orthodontic appliance designs for better constructability and functionality. The digital workflow experiences improvements through machine learning models which execute automated tasks to build 3D models and select materials so the production period shortens with fewer mistakes. The integration of artificial intelligence with additive manufacturing techniques holds great promise to elevate personalized healthcare standards by offering both better precision and effective care solutions for patients [8, 22].
Future studies emphasize the research on advanced materials which are specifically designed for 3D printing applications. The development of durable orthodontic devices with biocompatible properties now uses bioresorbable polymers and metal-based composites for creation. The materials used in this development enable stronger mechanical functionality in appliances alongside environmental sustainability benefits through decreased impact. Bioresorbable aligners serve as an example of therapeutic devices because they break down into natural matter after treatment thus eliminating waste disposal needs. Healthcare systems today require environmentally friendly solutions and which is why these developments have emerged [6, 24].
The future development of 3D printing requires enhanced availability of such technology to the wider public. Manufacturers work to decrease the expense of 3D printers and materials which enables them to serve smaller practices in regions with limited resources. The combination of cloud solutions and software advancements strengthens scalability because they enable medical staff to view and exchange digital designs through different platforms which creates environments that support collaboration. The projects emphasize making 3D printing technology available to everyone to guarantee worldwide access to its benefits [28, 32].
The direction of 3D printing technology depends heavily on improved systems of regulation and ethical practices development. Governments together with organizations continuously establish official guidelines to evaluate 3D-printed devices for orthodontics before their application and approval process. The initiatives will create better patient safety profiles and strengthen relationships between clinicians. The speed of healthcare 3D printing expansion requires medical institutions to solve issues regarding intellectual property ownership of digital workflows as well as custom designs. Future advancements in the technology will lead to a fundamental practice transformation in orthodontics which will introduce modernized individualized treatment systems [11, 35].
Types of 3D printing technologies in dentistry
The dental industry was transformed through 3D printing methods which enabled the creation of specified dental devices along with surgical guides and diagnostic assessment tools. The following section explains each of the 3D printing technologies which orthodontists and dentofacial orthopedists use for their practice:
Stereolithography (SLA)
The dental field extensively utilizes the SLA technology among all 3D printing technologies. Using a laser as its operative tool the system heals liquid resin into precisely shaped dental components one layer at a time. SLA printers excel for manufacturing orthodontic aligners and retainers together with surgical guides because they deliver precise details at high resolution levels. The dental professionals prefer SLA printing because its biocompatible resins deliver safe intraoral results [28, 33] as depicted in Figure 2.
Digital Light Processing (DLP)
What differentiates DLP from SLA is its usage of a digital projector which exposes complete layers simultaneously thus doing the printing process faster than SLA. DLP printers find widespread use in dental laboratories for the creation of dental molds as well as crowns and bridges. The fast processing capabilities along with high accuracy make these machines optimal for dental production laboratories that need quick manufacturing of orthodontic therapies (Figure 3) [1, 29].
Fused Deposition Modeling (FDM)
FDM operates as an economical 3D printing method that constructs products through sequential addition of thermoplastic filaments. Focused mainly for prototyping while making non-vital dental models FDM delivers limited precision when compared to SLA and DLP. Educational institutions widely use this technology to show dental structures and treatment preparation methods [34, 36].
The FDM printing procedure begins with placing thermoplastic resin filament within a 3D printer spool holder as shown in Figure 4. The print head nozzle requires reaching its temperature target before the filament enters for melting. The print head moves across three axes which extend from x to y and z. The molten filament becomes thin wadding that receives layer-by-layer lamination until solidification occurs during the cooling process. The printer platform descends after every finished layer enables the next layer to be applied during the lamination procedure. The 3D printing process will maintain its operation until designers create the complete product [40].
Selective Laser Sintering (SLS)
With SLS the laser instrument acts to weld together various types of powder materials including nylon and metal into complete volumes. SLS technology provides an efficient method for producing strong and elaborate dental parts such as orthodontic metal brackets along with prosthetic framework components. The valuable applications of SLS originate from its capability to produce strong and durable parts thus making it essential in dentofacial orthopedics [32, 37].
Figure 5 shows the SLS printing laser beam penetration mechanism scheme which represents the transmitted beam reflecting partially from the bottom printed layer to the powder layer [41].
PolyJet Printing
A build platform receives successive layers of liquid photopolymer which polymerize under UV light using PolyJet technology. The printing method enables multiple substance fabrication that allows the production of dental models with numerous surface textures and features. PolyJet technology mostly creates dental prototypes with realistic appearances along with anatomical models which help surgeons during their planning stage [30, 35].
PolyJet™ printers produce exact dental models and prosthetics, including crowns and dentures, with excellent detail and fit. Their great resolution and adaptability improves accuracy and patient outcomes (Figure 6) [42].
Bioprinting
The emerging field of bioprinting produces tissue-like structures through the usage of bio-inks which include living cells. Bioprinting demonstrates potential for regenerative dentistry by creating periodontal tissue scaffolds as well as maxillofacial bone grafts even though research is currently at an early phase (Figure 7) [33, 36].
Conclusion
3D printing has transformed orthodontics and maxillofacial surgery by introducing cutting-edge technologies aimed at enhancing treatment outcomes and patient comfort through the creation of personalized devices, precise surgical guides, and high-quality diagnostic models. While it has various advantages, such as shorter manufacturing times and higher treatment accuracy, obstacles remain in terms of equipment and material costs, compatibility issues with bioprinted devices, and the requirement for specialized training. The future holds immense potential, with breakthroughs in bioprinting and the incorporation of artificial intelligence to increase design and treatment efficacy, as well as material innovations that contribute to environmental sustainability. Because of these continual advancements, 3D printing is predicted to continue to change the face of medical care, becoming the best solution for creating individualized and effective therapies.
References
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Вплив 3D-друку в ортодонтії та щелепно-лицьовій хірургії: застосування, виклики та майбутні напрямки
1Університет Мосула, Мосул, Ірак
2Департамент охорони здоров’я Ніневії, Мосул, Ірак
Резюме. Передовий 3D-друк чинить значний вплив на стоматологічну практику, особливо в ортодонтичному та щелепно-лицьовому хірургічному застосуванні. Принципи адитивного виробництва дозволяють точно виготовляти медичні моделі разом із пристроями шляхом послідовного нанесення матеріалу відповідно до цифрових інструкцій. Точне виробництво індивідуальних ортодонтичних виробів, включаючи прозорі елайнери та хірургічні шаблони, за допомогою цієї технології забезпечує кращі результати для пацієнтів та підвищений рівень комфорту. Ключова перевага цієї технології полягає в можливості поєднання її з CAD/CAM та системами внутрішньоротового сканування, що дозволяє зменшити кількість людських помилок та пришвидшити виробничі процеси. Крім того, 3D-друк допомагає створювати точні діагностичні моделі для складних стратегій лікування та покращити діалог між медичним працівником та пацієнтом. Основні труднощі цієї методики включають значні витрати на обладнання та матеріали, а також потребу у кваліфікованих фахівцях. Розробка технології біодруку залишається предметом досліджень, оскільки вона дозволяє створювати живі тканини разом із застосуванням штучного інтелекту, спрямованого на вдосконалення технологій проєктування та виробництва. Вчені зосереджуються на двох основних аспектах створення біосумісних матеріалів з покращеними механічними властивостями та економічно ефективними технічними рішеннями, що підвищують їх доступність. 3D-друк забезпечує розширені діагностичні можливості разом із кращими варіантами лікування. Майбутнє лікування залежатиме від сталого технологічного прогресу в поєднанні з науковими дослідженнями, що закріпить цю технологію як життєво важливий медичний інструмент, що забезпечує точні результати лікування.
Ключові слова: 3D-друк, ортодонтія, щелепно-лицьова хірургія, адитивне виробництво.
Information about the authors:
Harith Ali Adel — Department of Conservative Dentistry, College of Medicine, University of Mosul, Mosul, Iraq. Ahmed Abdulsalan Abuljabbar — Department of Conservative Dentistry, Nineveh Health Department, Mosul, Iraq. |
Інформація про авторів:
Харіт Алі Адель — відділ консервативної стоматології, Медичний коледж Університету Мосула, Мосул, Ірак. Ахмед Абдулсалан Абулджаббар — відділ консервативної стоматології, департамент охорони здоров’я Ніневії, Мосул, Ірак. |
Received/Надійшла до редакції: 08.08.2025
Accepted/Прийнято до друку: 20.08.2025
