Digital technology began transforming orthodontics more than a decade ago. With the widespread adoption of 3D printing for clear aligner production, the industry has begun an era of affordable mass-customized appliances that make treatment deliveries faster, easier, and more comfortable for both professionals and patients.

Clear aligners continue to gain popularity with patients, as the discretion of so-called “invisible braces” appeals to both adults and adolescents. Meanwhile, technology enables practitioners to create aligners in-house, making this treatment plan financially viable for more patients. However, clear aligners continue to have clinical limitations, and in many cases traditional orthodontic treatment with brackets is still indicated and the preferable option.

Now, 3D printed indirect bonding trays are bringing labor and cost savings to bracket placement procedures.

An indirect bonding tray (referred to here as IBT, but also often shortened to IDB or referred to as transfer trays) is a custom-made appliance that precisely matches each patient’s dentition and bracket prescription to place multiple brackets at once. Since the preparation and careful placement can be done in advance virtually, patient chair time can be cut in half, saving the orthodontist valuable time.

Compared to other 3D printing resins for making IBTs, Formlabs IBT Resin offers optimized tear strength, translucency, and flexibility. Appliances printed in our resin are easier to use chairside, saving more time and money for the practice.

This Class I compliant resin was tested rigorously by Formlabs and industry experts. Beta testers liked the material’s accuracy, printability, and easy chairside use. Dr. Lisa Alvetro, an orthodontist in private practice in Sidney, Ohio, USA, beta tested the resin before its release.  “Clinically, I found indirect bonding trays printed using Formlabs IBT Resin to be accurate, easy to place and remove,” said Dr. Alvetro.

Dr. Alvetro has found that digital workflows like 3D printing allow her to delegate a lot of the day-to-day work to highly capable staff, such as Patricia Mitchell, a specialist in all the digital workflows used in their orthodontic practice.

For an orthodontic practice or lab that already uses digital tools, working with IBT Resin is easy.

With an intraoral scan and digital treatment plan, an orthodontist, technician, or assistant can generate the 3D model of an IBT in just a few minutes in any of several orthodontic design software programs. This file, exported as an STL, can be imported directly into Formlabs’ easy-to-use PreForm software and prepared for printing.

3D printing a part on a Formlabs SLA printer is a hands-off process. Once the printer is configured with the resin cartridge, resin tank, and build platform, and the 3D file is uploaded to the computer via Wi-Fi, ethernet, or USB cable, the print begins with a simple push of a button, and it doesn’t need any further attention until the print is complete.

After the part is printed, it needs to be post-processed, including washing in ≥96% isopropyl alcohol and post-curing. These steps can be automated with Form Wash and Form Cure. After curing, the IBT is complete, and can be cleaned, disinfected, and cared for with tools commonly found in orthodontic offices.

To dive into the details of the workflow, download our step-by-step application guide that starts with an intraoral scan and goes through the entire process.

With the addition of IBT Resin to our materials library, Formlabs has a comprehensive 3D printing solution for orthodontics. With the industry-leading Form 3B; easy-to-use Form Wash and Form Cure; powerful and free PreForm and Dashboard software; and expert service, there’s no better platform for digital orthodontics.