Instructions for Use (IFU) for printing aligners with DLP & LCD printe

This document provides application-specific instructions for the printing of orthodontic aligners using 3Dresyns® photopolymer resin systems on DLP and LCD vat photopolymerization printers.

This IFU must be used in conjunction with:

This document does not replace the general IFU documents and applies only to the production of orthodontic aligners.

Scope of application

This IFU applies to:

printing of orthodontic aligners and thermoforming molds
DLP and LCD vat photopolymerization systems
3Dresyns resin systems intended for orthodontic applications

This IFU does not apply to:

non-orthodontic dental devices
laser-based SLA systems unless specifically validated
off-label or unvalidated clinical workflows

Nature of aligner printing workflows

Orthodontic aligner printing is a highly application-sensitive process.

Final aligner performance depends on the interaction between:

resin formulation and version
printer technology and exposure strategy
printing orientation and layer thickness
post-processing and post-curing workflow
thermoforming conditions

Printed aligners or molds must therefore be considered process-dependent medical components, not intrinsic material outputs.

Printer and exposure considerations (DLP & LCD)

DLP and LCD printers expose entire layers simultaneously. As a result:

exposure time strongly influences dimensional accuracy
overcuring may affect surface fidelity and fit
undercuring may reduce mechanical stability and durability

Layer thickness, exposure time and light intensity must be optimized for each printer–resin combination.

Orientation and support strategy

Aligners or aligner molds should be oriented to:

minimize internal stresses
reduce layer stepping on functional surfaces
ensure uniform curing

Support structures must be placed to avoid contact with critical fitting areas whenever possible. Support removal and surface finishing may influence final fit.

Calibration and validation

Prior to production, users must:

calibrate exposure parameters for the selected resin and printer
validate dimensional accuracy using reference geometries
confirm reproducibility across multiple builds

Reference test files and internal quality controls should be used to verify consistency.

Post-processing and post-curing

Post-processing is a critical step in aligner workflows.

Washing, drying and post-curing conditions directly influence:

mechanical behavior
surface chemistry
biocompatibility performance
long-term stability

Post-processing must follow the qualified workflows defined in the applicable IFU. Deviations may significantly affect clinical performance.

Thermoforming considerations (if applicable)

When printed parts are used as molds for thermoforming:

mold dimensional accuracy is critical
surface quality affects aligner transparency and fit
excessive post-curing or surface roughness may impact thermoforming results

Thermoforming parameters must be validated independently by the user.

Biocompatibility and safety considerations

For clinical applications, users are responsible for:

selecting resin systems intended for orthodontic use
following the IFU for biocompatible resins
validating cleaning and post-curing effectiveness

Final medical device qualification and regulatory compliance remain the responsibility of the user or manufacturer.

Quality control and reproducibility

Users should implement internal quality controls including:

dimensional checks
visual inspection
batch traceability

Aligner workflows require controlled and documented processes to ensure reproducibility.

Limitations and responsibilities

This IFU provides application-specific guidance only.

Users are responsible for:

validating aligner performance for their clinical workflow
ensuring regulatory compliance
qualifying final medical devices

3Dresyns does not assume responsibility for clinical outcomes, device certification or regulatory approval.

Relationship to other Instructions for Use

This IFU must always be used together with:

Instructions for Use (IFU) for Vat Photopolymerization (SLA, DLP & LCD)

IFU for Biocompatible Resins, where applicable
any printer-specific IFU relevant to the selected equipment

In case of discrepancy, the most application-specific IFU prevails.

Governing principle

Orthodontic aligner printing is a multivariable, application-driven process. Final device performance depends on the complete material–printer–process–post-processing system and must be validated by the user.

Instructions for Use (IFU) for printing aligners with DLP & LCD printers