ArchForm – Direct Print Aligner Platform for Modern Orthodontics

ArchForm is an innovative orthodontic software solution that enables dental professionals to produce clear aligners in-house. Its Direct Print Aligner (DPA) module provides a complete digital workflow from scan to printed aligners, combining design automation, validated materials, and advanced 3D printing technology.

What Is Direct Print Aligner in ArchForm?

The Direct Print Aligner feature within ArchForm is a comprehensive system that merges design, production, and finishing of aligners using shape-memory photopolymers and validated printers. Unlike conventional thermoformed aligners, DPA prints the aligner shell itself, resulting in consistent thickness, superior fit, and reduced manual processing.

Key Features and Capabilities

• Automated Aligner Shell Generation: ArchForm automatically creates aligner shells with uniform thickness and optimized fit, including built-in supports for 3D printing.
• Shape-Memory Photopolymer: Printed aligners return to their original shape when warmed, providing precise and predictable tooth movement.
• Full Workflow Integration: From scanning to post-processing, every step is managed within one software platform.
• Validated Hardware Ecosystem: Works with approved 3D printers, curing units, and post-processing tools to ensure consistent results.
• In-Office or Lab Production: Ideal for both clinics and dental labs aiming to reduce costs and increase control over production.

Direct Print Aligner Workflow

1. Import Scan & Treatment Plan: Start by importing intraoral scans into ArchForm and setting up treatment stages.
2. Generate Aligner Shells: The software creates aligner geometry and optimized supports.
3. 3D Printing: Use validated printers and resins designed for DPA workflows.
4. Post-Processing: Aligners are centrifuged and cured in a nitrogen environment to ensure full polymerization.
5. Support Removal & Finishing: Supports are detached easily, and the aligners are polished and inspected for quality.
6. Delivery & Labeling: Aligners are labeled and prepared for patient use.

Benefits for Clinics and Labs

• Speed and Efficiency: Produce aligners the same day, eliminating external delays.
• Cost Savings: Reduce overall aligner production costs by up to 50%.
• Customization: Total control over case design, attachments, and aligner materials.
• Precision Fit: Uniform thickness and shape-memory materials ensure better tracking.
• Scalability: Perfect for single-chair clinics or large dental labs.

System Requirements and Compatibility

ArchForm supports both Windows and macOS. It integrates with most scanners and validated 3D printers. The workflow is compatible with STL, OBJ, and other standard CAD files. Post-processing requires a UV curing unit (preferably with nitrogen) and a centrifuge.

Why Choose ArchForm?

ArchForm offers a complete digital orthodontic ecosystem that brings aligner production into your hands. With its Direct Print Aligner module, you can streamline design, manufacturing, and delivery without relying on third-party labs. It reduces cost, speeds up treatment, and allows clinicians to maintain full control over every step of aligner production.

Practices adopting ArchForm have reported improved treatment precision and patient satisfaction, thanks to better fit and faster delivery. Whether you manage a single practice or operate a full-scale dental lab, ArchForm provides the tools to scale efficiently.

Implementation Tips

• Invest in validated hardware for best print accuracy and curing quality.
• Train staff on aligner staging, support editing, and post-processing.
• Start with simple cases before scaling up complex orthodontic workflows.
• Establish quality-control checkpoints for curing and labeling.
• Track resin consumption to optimize cost and yield.

Conclusion

ArchForm’s Direct Print Aligner solution is revolutionizing in-house orthodontics. By combining powerful design automation, shape-memory materials, and validated 3D printing technology, it enables dental professionals to produce aligners faster, cheaper, and with unmatched precision. For clinics seeking independence from third-party manufacturers, ArchForm is the modern choice for digital orthodontic innovation.

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