| Field | Value |
|---|---|
| ID | OA-0320 |
| Type | aligner |
| Category | aligner |
| Fixed/removable | removable |
| Primary function | sequential tooth movement / comprehensive orthodontic correction |
| Malocclusion target | crowding, spacing, mild-moderate Class I–II, open bite, relapse |
| Inventor | Align Technology (Invisalign, 1997); many lab-fabricated systems followed |
| First year | 1997 |
| Period | modern |
| Status | current |
| Uses TADs | occasionally (for anchorage in complex cases) |
| Material | polyurethane (PU) or PETG thermoforming sheet; or direct 3D-printed resin |
| Wear protocol | 20–22 hours/day; typically 7–14 days per aligner |
Clear aligners are custom-fabricated sequential trays that move teeth incrementally toward a planned final position. Each aligner in the series is programmed to move one or more teeth a small amount (typically 0.1–0.3 mm per aligner), and the patient changes to the next aligner every 7–14 days. Treatment can involve as few as 5–10 aligners (mild cases) or 40+ (comprehensive). Invisalign (Align Technology) dominates the market (~$8.3 billion global market in 2025, projected to billion by 2033), but lab-fabricated aligner systems — like CFL's Clear Fusion Aligners — allow orthodontists to offer in-house or lab-supported aligner treatment at lower cost and with greater control over clinical protocols.
Each aligner is manufactured to be slightly different from the current tooth positions — the elastic deformation of the tray as it is seated creates controlled forces that move teeth toward the designed positions. Attachments (small composite shapes bonded to teeth) provide grip and directionality for more complex movements like rotation and torque. Interproximal reduction (IPR) creates space for tooth movement when arch expansion alone is insufficient. The sequential nature of the series means each aligner builds on the last, with the cumulative effect producing the full treatment plan.
Mild-to-moderate crowding or spacing (ideal); anterior open bite correction; deep bite reduction; mild Class II or III dental (not skeletal); incisor torque correction; post-braces relapse correction; adult patients who prefer aesthetics over fixed brackets; patients with TMD or gingival sensitivity who cannot tolerate brackets. CFL's mild series targets 1–20 aligner cases; moderate for 21–40; comprehensive for complex/comprehensive treatment.
Skeletal malocclusions (Class II/III with significant jaw discrepancy) typically require fixed functional appliances, surgery, or TADs rather than aligners alone. Severe rotations, large tooth movements, and significant vertical corrections are challenging. Patient compliance is non-negotiable — aligners worn less than 20–22 hours daily fail to track. Patients who are not motivated should be offered fixed braces instead. Aligner therapy requires attachment bonding, IPR, and monitoring of tracking — a trained clinical team is essential.
Thermoformed aligners (traditional and most common):
2025); strong force consistency, flexibility, and durability.
cost-effective, widely used; growing segment.
thicker for final trays.
3D-printed aligners (emerging):
Carbon Lucentra); eliminates thermoforming step.
higher per-aligner cost currently.
Attachments: composite resin (placed by doctor; not lab-fabricated, but attachment templates are a lab deliverable).
The aligner lab workflow is: receive digital scan (STL) → run virtual treatment plan (staging software) → export staged models → print or mill models → thermoform aligners → trim and polish → QC check → ship. The planning software (proprietary or third-party like OrthoCAD, SureSmile, or in-house) is the core IP of any aligner lab. CFL's Clear Fusion Aligner series stages treatment using digital planning; the series price includes all aligners for the case tier. Extra aligners ("Oops" aligners for tracking issues; refinements) are priced separately. The "Oops" SKU is CFL's term for a mid-case correction aligner when a patient loses an aligner or tracking breaks down.
.
.
refinements or replacements.
deviates significantly.
per-case cost; not a CFL product but the competitive benchmark.
competitors.
relapse correction.
Research](https://www.grandviewresearch.com/industry-analysis/clear-aligners-market)
Aligners 2025 — Orthodontic Products](https://orthodonticproductsonline.com/treatment-products/aligners/whats-new-in-aligners-in-2025/)
Newswire](https://www.prnewswire.com/news-releases/clear-aligner-material-market-valued-at-usd-3-5-billion-in-2024--set-to-reach-usd-7-2-billion-by-2033-at-a-9-5-cagr-20262033---market-research-intellect-302652639.html)
Taglus](https://www.taglus.com/blogs/2026/03/the-future-of-orthodontic-materials-bioactive-smart-sustainable-digital-trends/)
ClearMoves](https://clearmovesaligners.com/clear-aligners-solutions-for-dental-labs/)
business notes.