How LuxCreo 3D Printing Transformed An
Orthodontic Workflow
“If you’re using any other kind of printer right now, you need to take a hard look at Voxel and their LuxCreo printers.”
Dr. David Carter, DDS
Founder of Carter Orthodontics in Augusta, SC and visionary behind
the Forever Aligned Club
A Testimonial from Dr. David Carter, Carter Orthodontics & Forever Aligned Club
In the ever-evolving world of orthodontics, few technologies have made as dramatic an impact on clinical practice and lab efficiency as direct-print aligners. For Dr. David Carter, founder of Carter Orthodontics in Augusta, SC and visionary behind the Forever Aligned Club, LuxCreo’s direct-printing system—implemented with the help of Voxel Dental—has become a complete game changer. Here's how.
First, watch the video. No time? Continue reading for the recap!
Problem: How to Scale Custom Retainers & Aligners
As the owner of Forever Aligned Club, Dr. Carter set out to create a scalable, affordable solution for long-term tooth alignment. His business model required the ability to produce single retainers and small batch aligners—sometimes as few as 1 to 5 aligners at a time.
But traditional workflows—thermoforming over printed models—were labor-intensive, dusty, and inefficient. As Dr. Carter explains:
“We had to get away from what I call indirect printing... I’ve been kind of waiting for a high-quality direct printed material and printer to come out—and LuxCreo provided that for us.”
Solution: Direct Printing with LuxCreo
Enter the LuxCreo iLux Pro system, available in the U.S. through Voxel Dental. This next-generation technology allowed Dr. Carter and his team to bypass the entire thermoforming and trimming process. The impact?
Cost-effective production of appliances
Cleaner workflow—no dust or trimming debris
Precision in force control through material thickness adjustments
“We can increase the thickness where we need it and decrease it where we need it—something you can’t do with thermoformed aligners.”
Clinical Advantage: Patented Designs, Made Possible
Dr. Carter has even patented orthodontic appliances that weren’t manufacturable using traditional techniques. Now, thanks to LuxCreo’s direct-printing capabilities, he’s finally able to bring those patented designs to life—including a clear spring retainer that enables minor movements without wires or attachments.
“Most patients want a clear retainer… I patented a design that wasn’t possible until LuxCreo came out.”
ROI & Cost Analysis
For Dr. Carter’s mid-sized dental lab, the return on investment (ROI) has been substantial. By eliminating multiple manual manufacturing steps, the lab has achieved:
💰 Lower per-unit costs—under $10 per appliance
📉 Reduced labor variability—no more depending on technician speed
⚙️ Fewer equipment replacements—less depreciation and maintenance
“You really can drill down and say, ‘This is how much each appliance costs me, period.”
Staff Satisfaction & Workflow Impact
Perhaps the most immediate benefit was felt by Dr. Carter’s team. The elimination of dusty trimming and model production created a safer, cleaner, and more enjoyable work environment.
“My staff absolutely loves it... They’re like, ‘Dr. David, this is so much better. Thank you.’”
He credits the LuxCreo team and Voxel Dental's onboarding experience with making the transition smooth:
“You guys have been great with the training from Voxel... It’s a paradigm shift, and the training had to be
exceptional.”
Final Verdict
Dr. Carter’s testimonial paints a clear picture: LuxCreo’s direct-print aligner system is not just an upgrade—it’s a revolution. Whether you’re running a single orthodontic practice or managing a growing lab, this technology delivers clinical freedom, operational efficiency, and patient-centered results.
“If you’re using any other kind of printer right now, you need to take a hard look at Voxel and their LuxCreo
printers.”
Ready to Upgrade Your Workflow?
If you're ready to ditch thermoforming, reduce production costs, and explore direct-print aligner technology, now is the time.
👉 Contact us to schedule a demo or get started today.
About LuxCreo
Leading platform for personalized medical and dental devices
LuxCreo is the leading platform for personalized medical and dental devices, dedicated to transforming patient care through innovation, speed, and customer success. We empower doctors to design, create, and deliver same-day treatments that enhance smiles, health, and well-being for a wider number of patients.
Our unique ecosystem supports dental and medical professionals with onsite, scalable solutions and flexible production with laboratory design and production services. LuxCreo helps doctors grow their practices and improve patient care by delivering more customized and effective treatments with convenience and precision.
For more information, contact us.
About Voxel
Voxel Dental is a dedicated team of dental technology consultants and support specialists, offering digital imaging and 3d printing solutions to dental practices across the United States and Canada. Our products enhance patient care while streamlining dental practice workflow. Starting in 2016, James Bonham, CEO of Voxel Dental, recognized that the future of dentistry would revolve around digital technologies. Since Voxel's inception, our goal has always been to be your digital dental workflow partner in devices support and consultation, from intraoral scanners to 3D printing. With over 80 years of combined dental experience, our services range from lab service consultation, additive manufacturing, and intraoral scanning to CBCT, pan/ceph imaging, robotics, lab products, sales and support. Plenty of other companies offer similar products but, from day one, Voxel Dental has strived to not only consult with you to find the appropriate technology for implementation but also to be an education and technology resource that supports you through each and every step of your digital dental journey. We strive to support not only the products we offer but also to provide advice and direction for clinical implementation into your practice or lab. Since 2016, Voxel has grown by leaps and bounds, incorporating new technologies and services into its repertoire and growing the Voxel Team. While Voxel is known for our stellar training and high-touch support for our products, we also maintain a deep and extensive knowledge base to provide clear and concise steps to maximize efficiency. From instructional courses to trade shows, we strive to be on the cutting edge of technology - not only in design but also in application. Based out of Houston, Texas, we serve the US and Canada, with representatives nationwide to ensure an unmatched customer experience. Digitally transform your practice with Voxel Dental Solutions.