Streamlining Orthodontics with LuxCreo’s Direct Print Aligner Workflow

LuxCreo’s fully integrated direct-print aligner ecosystem transforms orthodontic practices by delivering same-day, high-precision，shape memory clear aligners powered by ActiveMemory™ Polymer and advanced 3D printing technologies.

The Case for Direct Printing

Traditional thermoformed aligners are limited by irreversible material creep, uneven thickness, and rapid force decay, often requiring multiple refinements and extended treatment timelines. Direct 3D printing overcomes these drawbacks by fabricating aligners layer-by-layer from proprietary resins—most notably LuxCreo’s ActiveMemory™ Polymer (AMP)—ensuring consistent force delivery, precise fit, and the ability to restore geometry and strength via thermal activation.

Key Material Innovations

ActiveMemory™ Polymer (AMP)

• Stable Force Retention: <10% modulus variation between 25 °C and 37 °C
• Shape-Memory Restoration: Full geometric recovery within 0.1 mm after hot-water activation (> 60 °C)
• Biocompatible Resin System: Photocurable, multi-component architecture engineered for intraoral durability

By contrast, PET-G and TPU thermoformed plastics exhibit irreversible thinning and significant force loss over wear cycles. AMP’s dual-mechanism design uncouples intraoral stiffness from external shape recovery, enabling predictable orthodontic forces throughout treatment.

Unlock more about ActiveMemory™：https://luxcreo.com/4d-aligner/activememory-polymer

End-to-End Digital Workflow

1. Intraoral Scanning & Virtual Setup A high-resolution scan captures the patient’s dentition. Treatment planning software automates segmentation, staging, and virtual tooth movement simulations—eliminating physical models and manual adjustments. （Read the LuxCreo x AlliedStart scan-to-design integration press release) https://luxcreo.com/press-releases/luxcreo-alliedstar-integration/)
2. LuxDesign™ CAD Shell Creation Clinicians customize aligner thickness, offsets, and attachments within LuxCreo’s CAD platform, ensuring each shell matches the prescribed force profile and anatomical nuances.
3. LuxFlow™ Print Preparation Software Powered by 1-Click Automation: LuxFlow software streamlines every step of the 3D printed aligner workflow by automating model preparation, support generation, and slicing to meet demanding same-day throughput requirements. Imported STL files are automatically inspected and repaired to eliminate mesh irregularities, while intelligent orientation algorithms position each aligner for maximum print accuracy and minimal material usage.
4. Direct Printing with iLux Pro Dental Printer: a high-performance DLP 3D printing platform designed specifically for dental clinics, capable of producing up to 80 clear aligners per build with 50 μm accuracy, and featuring integrated automatic resin replenishment and temperature control to ensure stable, high-load operation and same-day delivery.
5. Automated Post-Processing:
6.  iLuxWash™: Solvent cleaning removes uncured resin
7.  iLuxCure™: UV-curing completes polymerization, achieving target mechanical properties

Support Removal & Surface Finishing: Automated systems streamline trimming and polishing

Thanks for Digital Polishing™ technology, enabling incredibly clear appliances direct from the printer without manual polishing required by competing solutions. This technology delivers 80% higher clarity while reducing polishing time by 75%, significantly streamlining the In-House 3D Printed Aligner production process.

6. Thermal Activation & Delivery Patients perform a simple hot-water soak to reactivate AMP’s shape memory, ensuring each aligner restores its original geometry and force before insertion.

Selecting the Right In-Office Printer

When evaluating an in-office printer, prioritize the following criteria to ensure seamless, high-volume production and exceptional print quality:

• Ease of Use and Workflow IntegrationLeverage LuxCreo’s 1-Click automation for truly hands-off operation—from LuxDesign™ import through LuxFlow™ print preparation—eliminating manual setup and minimizing user training.
• Reliable, Continuous OperationChoose a platform with proven long-term stability: the iLux Pro Dental Printer supports 24/7 usage with real-time system monitoring, automatic resin replenishment, and active temperature control to maintain consistent performance under heavy loads.
• Production CapacityMaximize throughput: the iLux Pro Dental Printer can produce up to 80 clear aligners per build, enabling same-day delivery without compromising accuracy.
• Accuracy BenchmarksEnsure clinical precision with sub-100 µm deviation across full-arch prints, delivering a perfect fit every time.
• Comprehensive Support and TrainingAccess LuxCreo’s global service network for on-site training, rapid technical support, and seamless upgrade pathways to keep your practice running at peak efficiency.
• Total Cost of OwnershipBalance upfront investment with ongoing resin, maintenance, and throughput costs—empowering you to scale confidently and deliver exceptional patient care.

LuxCreo’s buyer’s guide evaluates DLP , highlighting the iLux Pro’s superior speed, reliability, and compatibility with AMP resin.

Clinical and Operational Benefits

• Same-Day Delivery: Complete scan-to-aligner withinin ~ 3 hours, enhancing patient satisfaction and practice differentiation
• Reduced Refinements: Stable force profiles minimize mid-course corrections
• Enhanced Comfort: AMP’s balanced load-deflection behavior avoids excessive initial forces and material relaxation
• Sustainability: Digital storage of designs eliminates resin models; on-demand printing reduces inventory waste
• ActiveMemory™ Shape-Retention

Equivalent to “wearing a fresh aligner every day,” ActiveMemory™ polymer maintains optimal force throughout treatment. A brief daily warm-water soak also enhances hygiene.

• Fewer Attachments, Better Aesthetics

Minimizes auxiliary attachments for simpler clinician workflows and improved patient comfort.

• Precision Local Thickness Control

Enables fine-tuned stiffness zones and exact wall thicknesses for truly personalized treatment designs.

• On-Demand Chairside Production

Direct printing delivers patient-ready aligners the same day, dramatically shortening wait times and elevating the patient experience.

Best Practices of dental clinics and labs

As the #1 3D Digital Dental Printer and one of the fastest-growing names in the dental industry, iLux Pro Dental Printing Solution has become the go-to choice for dental clinics and labs worldwide. More and more practices are adopting this cutting-edge technology for its ability to rapidly produce high-precision clear aligners and other orthodontic products.

Dr. Bill Layman shared their experience: “With the benefit of hindsight, I wish I would have researched more on LuxCreo before I purchased SprintRay. I now own two LuxCreo machines.”

Dr. Neil Warshawksy and his dental technicians dive into how LuxCreo’s iLux Pro Dental Printer has revolutionized their workflows and enhanced the production of aligners, retainers, nightguards, orthodontic models, and more.

Hear directly from dental clinics and labs—insights and feedback of iLux Pro dental solution：

Conclusion

LuxCreo’s direct-print aligner workflow—anchored by ActiveMemory™ Polymer, LuxDesign™, LuxFlow™, and iLux Pro Dental Printer —redefines clear aligner therapy. By delivering unmatched precision, rapid turnaround, and sustainable operations, it empowers orthodontic practices to elevate patient care and streamline clinical operations. Contact LuxCreo today to schedule a demo and embark on the future of in-office aligner fabrication.