Clear aligners have transformed orthodontics, offering patients a discreet and comfortable alternative to traditional braces. While thermoformed aligners have been the industry standard for years, recent advancements in 3D printing have led to the rise of direct print aligners (DPA). Both methods achieve the same goal—gradually moving teeth into alignment—but their manufacturing processes, precision, and efficiency differ significantly.

In this article, we’ll compare thermoformed aligners and direct print aligners to help clinics, labs, and distributors understand which option best fits their needs.

1. Manufacturing Process

Thermoformed Aligners:

• Start with a 3D-printed dental model of the patient’s teeth.

• A thermoplastic sheet is heated and vacuum-formed or pressure-formed over the model.

• The aligner is trimmed, polished, and finished manually.

Direct Print Aligners:

• Aligner is digitally designed and directly 3D-printed in biocompatible resin.

• Requires minimal post-processing (curing, polishing).

• Skips the intermediate step of printing physical models.

 Advantage: Direct printing eliminates extra steps, reducing time and material use.

2. Precision & Fit

Thermoformed Aligners:

• The thermoforming process can introduce slight distortions due to heating and stretching of plastic.

• Manual trimming and finishing may affect consistency.

Direct Print Aligners:

• Printed directly from the digital design, offering higher precision.

• Uniform thickness and sharper detail capture lead to a more accurate fit.

 Advantage: Direct print aligners generally offer superior precision and consistency.

3. Turnaround Time

Thermoformed Aligners:

• Requires multiple steps (model printing + forming + trimming).

• More labor-intensive.

• Turnaround depends heavily on lab efficiency.

Direct Print Aligners:

• Streamlined digital workflow reduces production time.

• Enables same-day or next-day delivery in some cases.

Advantage: Direct print aligners allow faster treatment delivery.

4. Material Properties

Thermoformed Aligners:

• Traditionally made from multilayer thermoplastics.

• Known for strength, elasticity, and proven clinical track record.

Direct Print Aligners:

• Made from specialized resins designed for flexibility and biocompatibility.

• Still relatively new in clinical use compared to thermoformed materials.

Advantage: Thermoformed aligners have more long-term clinical validation, while direct print materials continue to evolve.

5. Cost & Efficiency

Thermoformed Aligners:

• Higher material waste (models, trimming excess plastic).

• Requires more labor and equipment (3D printer + thermoforming machine).

Direct Print Aligners:

• More cost-efficient—no physical models, less waste.

• Lower manual labor requirement.

• Initial investment in high-quality 3D printers and resins may be higher.

Advantage: Direct printing offers better long-term efficiency and scalability.

6. Patient Experience

Thermoformed Aligners:

• Proven comfort and durability.

• Widely trusted by orthodontists and patients.

Direct Print Aligners:

• Thinner, lighter, and smoother edges due to digital precision.

• Some studies suggest higher comfort and aesthetics.

Advantage: Direct print aligners may provide a more comfortable patient experience.

Conclusion: Which is Better?

Both thermoformed and direct print aligners play a significant role in modern orthodontics:

• Thermoformed Aligners are time-tested, reliable, and backed by decades of clinical use.

• Direct Print Aligners represent the future of aligner production—faster, more precise, cost-efficient, and potentially more comfortable for patients.

For clinics and labs, the choice often comes down to balancing familiarity and proven results with innovation and efficiency. As direct print technology and materials continue to advance, it’s likely they will become the new standard in clear aligner manufacturing.

Looking to start offering in-house aligners or enhance your existing workflow? Craft Align can support you with precise treatment planning and clear aligner design. We provide print-ready STL files for both thermoforming and Direct Print Aligners (DPA).