Abstract: A method for localized heat treatment of a region of an orthodontic wire employs a hot air source having a maximum flow rate of approximately 6-10 liters per minute to selectively heat a small region of the wire above a predetermined temperature to change its metallurgical properties while the wire is held in a desired shape by an instrument or fixture. After the wire has been maintained at temperature for the required period of time, it can be released and allowed to cool. For example, these capabilities are well-suited for shape-setting localized regions of austenitic Ni—Ti wire and for stress-relieving and normalizing heavily-worked stainless steel wire.

Abstract: A method for creating features in an orthodontic aligner employs a hot air source having a maximum flow rate of approximately 10 liters per minute to selectively heat a small local region of the aligner above the thermoforming temperature of the aligner material. The heated region of the aligner is manipulated to form the desired feature, and then allowed to cool to solidify the feature. These features can be used, for example, to directly impart therapeutic forces on teeth, or for attachment of aligner auxiliaries to the aligner.

Abstract: A method for producing orthodontic aligners uses a CAD system to modify a digital model of the patient's oral anatomy to incorporate features that accommodate attachment of aligner auxiliaries to the completed aligner(s).