Abstract: An aesthetically pleasing orthodontic appliance which is formed by casting a molten precious metal alloy, a major portion of which is gold and a minor portion of which is platinum, such appliance having a contoured, tooth-engaging surface with at least one irregularity therein to permit a dental adhesive to form a mechanical bond with the appliance, the irregularity being a recess which extends into the interior of the appliance to reduce the weight thereof, and a "lost wax" type of process for forming such a precious metal alloy orthodontic appliance using an organic orthodontic appliance as a form, the contoured, tooth-engaging rear surface of such organic orthodontic appliance being treated to form at least one irregularity therein corresponding to the irregularity that is desired in the precious metal alloy orthodontic appliance.