The Freedom to Scale Orthodontics Your Way:
How Dr. Bill Layman Combines In-House Production and LuxCreo Aligner Services to Maximize Flexibility and Growth
"With LuxCreo, I'm not locked into one workflow—I can decide, case by case, what's truly the smartest choice: print in-house, outsource, or blend both for the best result."
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Dr. Bill Layman, DMD, MBA
Straighten Up Orthodontics
What is the “Hybrid Workflow”?
Take full control of the entire process, completing all 3D printing in-office using the LuxCreo digital workflow.
Post-scan, hand off the entire case to LuxCreo's expert team for manufacturing and delivery.
Print select stages in-house and outsource the remaining stages to trusted partners.
Table of Contents:
1. Meet Dr. Layman and His Workflow Challenge
2. Introduction to Hybrid Workflow from LuxCreo: The Make-or-Buy Decision
3. Implement in Your Practice: Two Case Examples
4. Business Benefits & Conclusion
For many orthodontic practices, adopting digital workflows raises an important question: Should aligners be produced in-house or outsourced?
For Dr. Bill Layman, owner and lead orthodontist at Straighten Up Orthodontics in Clearwater, Florida, the answer isn't either-or. It's both.
As an orthodontist committed to innovation and efficiency, Dr. Layman believes the most successful practices aren't locked into a single production model. Instead, they maintain the flexibility to make the smartest decision for every patient, every case, and every stage of growth.
With LuxCreo, Dr. Layman doesn't have to choose between bringing production in-house or sending everything to a third-party manufacturer. He has the freedom to decide what makes the most sense every time.
And you can too.
A Hybrid Workflow Built Around Your Practice -Not the Other Way Around
Every orthodontic practice experiences fluctuations in patient volume, staffing, and production demand. Rather than forcing his practice into a rigid workflow, Dr. Layman uses LuxCreo to create a hybrid production model that adapts to those changing demands.
Depending on the situation, he can:
- Produce the full case in-house using LuxCreo’s digital workflow.
- Outsource entire cases to LuxCreo’s 4D Express™ aligner service or another trusted-third party provider
- Hybrid Workflow: Print selected stages in-house while outsourcing the remaining stages.
According to Dr. Layman, about 30% of his cases are produced fully in-house, 40% are fully outsourced, and the other 30% are produced using the hybrid workflow.
This flexible approach gives him complete control over how every case is produced. Whether speed, staffing, printer availability, or economics drive the decision, the workflow adjusts to the needs of the practice; not the other way around.
The
“Make-or-Buy” Decision
Dr. Layman describes every production decision using a simple business principle known by economists as the "make-or-buy" decision.
Every organization constantly evaluates whether something should be produced internally or purchased from an outside partner. Dr. Layman says:
Orthodontic production follows the same logic. Each aligner case requires balancing factors such as:
Instead of making the same decision every time, Dr. Layman evaluates each case individually.
How to Evaluate Your Make-or-Buy for Every Aligner Case?
This proven approach from Dr. Layman can be easily implemented in your practice.
- How long will this case take?
- Does my patient need their appliance right away?
- Even though there’s a cost associated with outsourcing to a trusted partner like 4D Express™, will keeping my printer and staff open for another upcoming appointment make more economical sense?
These are all questions you should ask yourself before making a decision about your practice workflow.
Scenario 1:
In-house Printing
Patient A came to Dr. Layman’s office looking to correct her lower anteriors that moved after a failed bottom retainer. The catch?
Scenario 2: Outsourcing to LuxCreo
Patient B came to Dr. Layman’s office looking for pediatric aligner treatment. She was missing teeth 6 and 11. There was no rush to complete her case, and Dr. Layman knew it would take many trays to complete.
Business Benefits
Grow Without Overbuilding
As practices expand, it's easy to assume additional growth requires more printers, more staff, and more physical space. Those investments become permanent fixed costs... but patient volume isn’t always permanent. By balancing in-house production with outsourced manufacturing, Dr. Layman can continue growing without investing in additional infrastructure.
Better Financial Decisions
Every aligner case has different economics. Some are ideal for complete in-house production. Others require enough labor or printer time that outsourcing becomes the more profitable decision. Whether he’s choosing one, or combining the two approaches, LuxCreo gives practices the flexibility they need to make the smartest financial decisions possible. According to Dr. Layman, his practice saves an average of $18 per tray when they produce in-house as opposed to outsourcing. At the same time, outsourcing saves his office 25 hours of production each month and eliminates two appointments, allowing him to treat more cases. It’s all about the Make-Buy Decision.
Optimize Cash Flow
Note: Data reflects Dr. Layman’s practice. Results may vary by location, case type, and production model.
Conclusion: Every choice is aimed at maximizing financial and operational benefits across different cases.
Maximize Existing Equipment
LuxCreo printers aren't dedicated solely to aligners. They're capable of producing a wide range of same-day dental applications, such as retainers, night guards, and surgical guides.
When demand for clear aligners surges, outsourcing a portion of that production preserves existing 3D printer capacity for higher-value items. This strategic allocation avoids capital expenditure on new equipment while maximizing the overall return on investment (ROI) and net utility of current assets.
Better for Patients
For larger aligner cases, Dr. Layman can print the first stages immediately, so treatment begins without delay while the remaining aligners are manufactured through 4D Express™ or another trusted aligner service provider. Patients receive faster treatment starts without sacrificing efficiency behind the scenes that could inadvertently affect their treatment outcomes.
Freedom Creates Better Orthodontics
Digital orthodontics shouldn't force practices to choose between in-house production and outsourcing.
It should provide the flexibility to make the right decision every time.
For Dr. Bill Layman, that's exactly what LuxCreo delivers.
Whether producing every aligner chairside, outsourcing complex production, or combining both approaches within the same case, he maintains complete control over how his practice operates.
That freedom allows Straighten Up Orthodontics to grow sustainably, control costs, maximize existing resources, respond to changing demand, and continue delivering exceptional patient care—all without locking into unnecessary fixed expenses. And it can do the same for your practice too.
Find the Right Aligner Production Model for Your Practice
Whether you’re considering bringing aligner production in-house, outsourcing it, or combining both approaches, the right model depends on your practice, case volume, and goals.
Book a Demo to see how LuxCreo can fit into your workflow.