Abstract: A system includes a carrier film including an outer surface and an inner surface. The inner surface is configured to contact rollers. The system further includes a first blade configured to form a layer of resin on the outer surface of the carrier film. The system further includes a second blade configured to prevent printed features from contacting the first blade. The system further includes a build platform. A portion of the layer of resin is to be added to an object being formed on the build platform.

Abstract: The present disclosure provides multi-material orthodontic appliances useful for expanding a palate or arch of a patient, and, in some case, moving one or more teeth of the patient from a first to a second location according to a treatment plan. Further provided herein are methods for producing and using such multi-material orthodontic appliances on an individualized basis where each appliance is tailored to the specific treatment requirements of a patient.

Abstract: Provided herein are curable compositions for use in a high temperature lithography-based photopolymerization process, a method of producing crosslinked polymers using said curable compositions, crosslinked polymers thus produced, and orthodontic appliances comprising the crosslinked polymers.

Abstract: A 3D printer comprises a platform, a dispenser and a light source. A heating element heats a material and a nozzle extrudes the heated material onto the platform to form a first layer, having a first shape specified by one or more digital files. The first shape corresponds to a first minimum line width based on a diameter of the nozzle. The light source emits a light beam that is directed onto the first layer according to the one or more digital files to cure a portion of the first layer to create a first cured layer that corresponds to a second shape of a 3D object specified by the one or more digital files. The light beam has a beam diameter that is smaller than the diameter of the nozzle, and the second shape has a second minimum line width that is smaller than the first minimum line width.

Abstract: A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape.

Abstract: The present disclosure provides methods, systems, devices, and kits for creating composite materials from a single resin, the composite materials having multiple continuous phases. The disclosure includes a process to three-dimensionally print objects (e.g., orthodontic appliances) with composite properties. In some aspects, the composite properties are formed from a single formulation with components that, when processed, have hard and soft continuous phases. In some aspects, the composite properties are formed by separately processing the hard phase components and the soft phase components. In some aspects, the composite materials and devices are three-dimensionally printed using the processed material.

Abstract: The present application relates to components, such as dental apparatuses, having geometrical features to facilitate post-fabrication cleaning, including methods of fabricating the same. In one embodiment, a dental apparatus, such as a retainer, an aligner, or a dental attachment placement appliance, comprises one or more concave surfaces for which one or more apertures is formed therethrough at or near a maximum depth of a given concave surface.

Abstract: A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape.

Abstract: Dental apparatuses, such as palatal expanders and aligners, and methods of forming them. The dental apparatuses may formed by printing different regions of the device with different properties, including hybrid regions formed between adjacent regions having different physical characteristics for performing different functions when worn by a patient as part of a dental treatment. The different regions may be joined together by a transition region configured to hold adjacent regions together during use and provide advantageous properties.

Abstract: Dental apparatuses, such as palatal expanders, and methods of forming them. The dental apparatuses may have multiple regions having different physical characteristics for performing different functions when worn by a patient as part of a dental treatment. The different regions may be made of different materials, or different combinations of materials, based on rigidity, flexibility and/or other physical characteristics. For palatal expanders, the different regions can include a tooth engagement region adapted to engage with the patient's teeth and a palatal region adapted to exert an expansion force across the patient's palate. The different regions may be joined together by a junction or a transition region configured to sufficiently hold adjacent regions together during use.

Abstract: Dental apparatuses, such as palatal expanders, attachment templates, mandibular repositioning aligners, and a variable property aligners, and methods of forming them. The dental apparatuses may have multiple regions having different physical characteristics for performing different functions when worn by a patient as part of a dental treatment. The different regions may be made of different materials, or different combinations of materials, based on rigidity, flexibility and/or other physical characteristics. The different regions may be joined together by a junction region configured to sufficiently hold adjacent regions together during use.

Abstract: Provided herein are systems and processes to control multiple temperatures in additive manufacturing. Such temperature control adjusts polymer properties and facilitates processing of materials to form 3D objects. The systems and processed disclosed herein also facilitate the processing of typically difficult-to-process materials and deliver such materials to a photocuring zone configured to photopolymerize materials into 3 dimensional objects with a layer-by-layer process. Such processes can include the steps of heating a resin to a flowable temperature, applying the resin to a carrier, cooling the film to increase viscosity or to solidify the resin, and applying the film containing the resin onto an area being printed, then photocuring the film. Also provided herein are resins and related polymer materials having properties that are tunable with exposure to more than one temperature zone. The formed polymers can include multiple regions of polymer material, each independently having distinct properties.

Abstract: Provided herein are curable compositions for use in a high temperature lithography-based photopolymerization process, a method of producing crosslinked polymers using said curable compositions, crosslinked polymers thus produced, and orthodontic appliances comprising the crosslinked polymers.

Abstract: This disclosure provides low-viscosity resins for producing polymers with properties suitable for use in various mechanical appliances, such as orthodontic appliances (e.g., aligners). The low-viscosity resins may be photo-curable and can be used with direct fabrication methods and equipment. In various embodiments, the polymeric materials produced from the low-viscosity resins described herein have high toughness while remaining resistant to stress relaxation. Low-viscosity, photo-curable resins described herein have reduced hydrogen bonding in comparison to traditional materials (e.g., materials having high urethane content) used in orthodontic appliances.

Abstract: Provided herein are curable compositions for use in a high temperature lithography-based photopolymerization process, a method of producing crosslinked polymers using said curable compositions, crosslinked polymers thus produced, and orthodontic appliances comprising the crosslinked polymers.

Abstract: A method of three-dimensional (3D) printing includes heating a photo-curable material and extruding the photo-curable material from a nozzle to form a first layer of an object according to a digital file, wherein the first layer has a first shape specified by the digital file, and wherein the first shape has a first minimum line width based on a diameter of the nozzle. The method further includes directing a light beam onto the first layer according to the digital file or an additional digital file to cure a portion of the first layer, wherein the cured portion of the first layer has a second shape, wherein the second shape may comprise features that are smaller than the first shape.

Abstract: Provided herein are curable compositions for use in a high temperature lithography-based photopolymerization process, a method of producing crosslinked polymers using said curable compositions, crosslinked polymers thus produced, and orthodontic appliances comprising the crosslinked polymers.

Abstract: Provided herein are curable compositions for use in a high temperature lithography-based photopolymerization process, a method of producing crosslinked polymers using said curable compositions, crosslinked polymers thus produced, and orthodontic appliances comprising the crosslinked polymers.