CUSTOM-MADE BRACKETS FABRICATION BY AN ADDITIVE MANUFACTURING PROCESS FOR ORTHODONTIC TREATMENT

Brackets are basic elements of orthodontic systems. Traditionally, they are produced by a powder-injection mass production process, by which it is difficult to develop individualized products. This study applies computer-aided engineering techniques, including digitizing, virtual model design, and additive manufacturing (AM) to orthodontics for the production of customized brackets. First, a digital model of the teeth was obtained via a 3D scanning process, in which an individual teeth plaster mold was digitized; customized brackets were then designed based on the model, and physical brackets were rapidly fabricated by AM processing. Finally, key dimensional measurements of the brackets were taken to confirm whether the brackets fulfilled the functional requirements for clinical usage. By this process, brackets designed for different teeth pads were obtained by digital planning, CAD design and rapid manufacturing. The custom-made brackets include complete dental profile information, and increase the efficiency of treatment, save clinical setup time, and reduce the treatment duration and cost for the patient. The direct manufacture of metal brackets by an AM process is a modern method with great potential to be used in the generation of customized brackets for orthodontic treatment.