Abstract: A method includes identifying first geometry of a first mold associated with a first dental arch and a second geometry of a second mold associated with a second dental arch. The method further includes determining, based on the first geometry and the second geometry that the first mold and the second mold are to be used for simultaneous forming of a first dental appliance and a second dental appliance on a plate in a dental appliance manufacturing system. The method further includes causing, based on the first geometry and the second geometry, one or more portions of the dental appliance manufacturing system to be configured to form the first dental appliance and the second dental appliance.

Abstract: A method includes identifying one or more images of a mold of a dental arch, identifying a digital model corresponding to the mold of the dental arch, providing the one or more images and the digital model as input into a trained machine learning model, receiving, from the trained machine learning model, output, and determining, based on the output, whether the mold matches the digital model.

Abstract: Methods for verifying manufacturing data are provided. In some embodiments, a method includes retrieving a fabrication data package including manufacturing data for one or more dental appliances, where the manufacturing data includes one or more treatment stages for repositioning a patient's teeth using the one or more dental appliances. The method can include determining whether there is an error in the manufacturing data of the fabrication data package. In response to a determination that there is an error in the manufacturing data, the method can include requesting a corrected fabrication data package, and transmitting the corrected fabrication data package to at least one fabrication terminal configured to execute a fabrication process for manufacturing the one or more dental appliances.

Abstract: A method of 3D printing comprises extruding one or more photo-curable materials from a nozzle to form a first layer that has a first shape specified by the one or more digital files, wherein the first shape corresponds to a first minimum line width that is based on, and narrower than, a diameter of the nozzle. The method further includes directing a light beam 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, wherein the first cured layer corresponds to a second shape of a first layer of a 3D printed orthodontic aligner, wherein the light beam has a beam diameter that is smaller than the diameter of the nozzle, and wherein the second shape has a second minimum line width that is smaller than the first minimum line width.

Abstract: Systems for volume manufacturing of items are provided. In some embodiments, a fabrication system is configured to retrieve a fabrication data package including manufacturing data. The system can verify the manufacturing data of the fabrication data package, and transmit the fabrication data package to at least one fabrication terminal configured to perform at least one fabrication process in accordance with the manufacturing data of the fabrication data package. If a predefined fabrication processing time period has not expired, the system can determine a process load associated with at least one additional fabrication data package, and repeating the above processes for the at least one additional fabrication data package, if the process load of the at least one additional fabrication data package is less than a predetermined process load of the fabrication system. If the predefined fabrication processing time period has expired, the system can generate a status report.

Abstract: Methods and systems for post-processing molds are provided. In some embodiments, a method includes using a layer-by-layer build process on a polymeric resin to produce a plurality of aligner molds. The method can include transporting the plurality of aligner molds to a resin removal station. The method can also include applying high pressure air to the plurality of aligner molds to remove residual material from the plurality of aligner molds. The residual material can include excess polymeric resin. The method can further include collecting the excess polymeric resin.

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: Systems, methods, and computer-readable media for identifying and facilitating review of outlier treatment plans. A method includes receiving an initial three-dimensional (3D) model of an initial arrangement of a patient’s teeth and generating a first final 3D model of a first final arrangement of the patient’s teeth based on the initial 3D model of the initial arrangement of the patient’s teeth. The method further includes comparing the first final arrangement of the patient’s teeth with a set of a plurality of final arrangements of teeth from previous treatment plans of past patients and determining whether the first final arrangement of the patient’s teeth satisfies one or more outlier criteria based on the comparing. Responsive to determining that the first final arrangement of the patient’s teeth satisfies the one or more outlier criteria, an orthodontic treatment plan comprising the first final 3D model of the first final arrangement of the patient’s teeth is classified as a clinical risk.

Abstract: Systems for volume manufacturing of items are provided. In some embodiments, a fabrication system is configured to retrieve a fabrication data package including manufacturing data. The system can verify the manufacturing data of the fabrication data package, and transmit the fabrication data package to at least one fabrication terminal configured to perform at least one fabrication process in accordance with the manufacturing data of the fabrication data package. If a predefined fabrication processing time period has not expired, the system can determine a process load associated with at least one additional fabrication data package, and repeating the above processes for the at least one additional fabrication data package, if the process load of the at least one additional fabrication data package is less than a predetermined process load of the fabrication system. If the predefined fabrication processing time period has expired, the system can generate a status report.

Abstract: Methods for volume manufacturing of a plurality of unique items are provided. In some embodiments, a method includes: (a) initiating a predefined fabrication processing time period, (b) retrieving a fabrication data package containing manufacturing data, (c) verifying the fabrication data package for accuracy and completeness of the manufacturing data contained therein, and (d) performing at least one fabrication process in accordance with the manufacturing data contained in the fabrication data package. If the predefined fabrication time period has not expired, the method can include repeating (b) through (d). If the predefined fabrication time period has expired, the method can include generating a status report.

Abstract: A system and method for post-processing of polymeric items having a liquid component and a predetermined heat deflection temperature is provided. The system includes a washing station to spray water at elevated temperature and pressure on the items while maintaining the temperature of the item below the heat deflection temperature. Then using a water distillation system to separate the water from the water mixed with the liquid polymer component by evaporating the water using heating coils with surface that is not conducive to adhesion of the liquid polymer component and then condense the water vapor into liquid water. The system may further include a spin station to separate the liquid polymer component by spinning the item. The system may further include one or more processing stations to rinse the item, dry the item, cure the item, remove the item from a tray to which the item may be attached and clean trays after removing the item.

Abstract: Dental appliances, materials, and methods of forming such appliances and materials for improved laser marking are provided herein including the use of textured and/or roughened surfaces to enhance laser marking.

Abstract: A system and method for post-processing of polymeric items having a liquid component and a predetermined heat deflection temperature is provided. The system includes a washing station to spray water at elevated temperature and pressure on the items while maintaining the temperature of the item below the heat deflection temperature. Then using a water distillation system to separate the water from the water mixed with the liquid polymer component by evaporating the water using heating coils with surface that is not conducive to adhesion of the liquid polymer component and then condense the water vapor into liquid water. The system may further include a spin station to separate the liquid polymer component by spinning the item. The system may further include one or more processing stations to rinse the item, dry the item, cure the item, remove the item from a tray to which the item may be attached and clean trays after removing the item.

Abstract: A three-dimensional (3D) object comprises a plurality of layers representative of an additive manufacturing process, wherein each layer of the plurality of layers approximately has a first thickness. A first layer of the plurality of layers forms at least a portion of a first surface of the 3D object, the first layer comprising a support region and an overcure region, wherein the first layer approximately has the first thickness at the support region and a greater second thickness at the overcure region. A support mark is included at the support region, wherein the support mark is inset from a first surface profile of the 3D object defined by the overcure region.

Abstract: A shell removal device includes a platform configured to secure a mold. An untrimmed shell is formed over the mold. The shell removal device further includes a drive mechanism configured to move the platform away from the untrimmed shell responsive to sensor data indicative that the untrimmed shell has begun to separate from the mold.

Abstract: A method includes identifying first geometry of a first mold associated with a first dental arch and a second geometry of a second mold associated with a second dental arch. The method further includes determining, based on the first geometry and the second geometry that the first mold and the second mold are to be used for simultaneous forming of a first dental appliance and a second dental appliance on a plate in a dental appliance manufacturing system. The method further includes causing, based on the first geometry and the second geometry, one or more portions of the dental appliance manufacturing system to be configured to form the first dental appliance and the second dental appliance.

Abstract: A method of manufacturing a three-dimensional (3D) object may include fabricating a support structure and fabricating the 3D object on the support structure, wherein the support structure contacts the 3D object at a support region of the 3D object. The method further includes overcuring the 3D object at an overcure region of the 3D object, wherein the overcure region is distinct from the support region, and removing the support structure from the 3D object. After removal of the support structure, a support mark remains on the 3D printed object where the support structure had contacted the 3D object, wherein the overcure region of the 3D object projects past the support mark.

Abstract: A system and method for post-processing of polymeric items having a liquid component and a predetermined heat deflection temperature is provided. The system includes a washing station to spray water at elevated temperature and pressure on the items while maintaining the temperature of the item below the heat deflection temperature. Then using a water distillation system to separate the water from the water mixed with the liquid polymer component by evaporating the water using heating coils with surface that is not conducive to adhesion of the liquid polymer component and then condense the water vapor into liquid water. The system may further include a spin station to separate the liquid polymer component by spinning the item. The system may further include one or more processing stations to rinse the item, dry the item, cure the item, remove the item from a tray to which the item may be attached and clean trays after removing the item.

Abstract: Embodiments relate to automating removal of an untrimmed shell from a mold. In one embodiment, a shell removal device includes a body and a platform disposed within the body. The platform is configured to secure a mold that has an untrimmed shell formed over the mold. The shell removal device further includes a cover configured to secure the untrimmed shell to an upper surface of one or more sidewalls of the body and provide a seal between a lower surface of the untrimmed shell and the upper surface of the one or more sidewalls of the body. The shell removal device may include a media inlet in the body to permit pressurized media into the interior of the body to cause a pressure differential between an upper surface of the untrimmed shell and the lower surface of the untrimmed shell to cause the untrimmed shell to release from the mold.

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.