ArticleFrontiers in dental medicine2026
Thickness distribution and site-specific variability of thermoformed multilayer clear aligners: an
Article in Frontiers in dental medicine, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
Introduction: Thermoforming is a critical step in the fabrication of clear aligners and is associated with non-uniform deformation of thermoplastic materials, resulting in non-uniform thickness distribution. Because aligner thickness directly influences stiffness and force delivery, such variability may affect the accuracy and predictability of orthodontic treatment. Aim: This study aimed to evaluate the thickness distribution of thermoformed clear aligners across different tooth regions and anatomical sites, with a focus on identifying patterns of non-uniform material thinning. Methods: Ten thermoformed aligners fabricated from 760 µm multilayer thermoplastic sheets (Zendura FLX) were analyzed Results: Significant differences in thickness were observed among tooth regions ( Conclusion: Thermoformed clear aligners exhibit pronounced and systematic non-uniform thickness distribution strongly influenced by tooth morphology and local geometry characteristics. This non-uniform thickness distribution may contribute to variations in force delivery and should be considered in aligner design and clinical application.
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