Abstract: Thermoforming methods of making orthodontic appliances and orthodontic appliances preforms employ a barrier sheet positioned between an appliance sheet and a dental model during the forming step. The thermoformed orthodontic appliances are more pellucid than appliances thermoformed without the barrier sheet.

Abstract: Processes for forming orthodontic appliances and other dental inserts comprise scanning a patient's dental arch or a mould of a dental arch such as a traditional plaster mould, to form a digital dental arch file corresponding to the size and position of the patient's dental arch. The digital dental arch file contains data corresponding to a plurality of dimensions corresponding to portions of the patient's dental arch. The disclosed methods include the step of modifying the digital dental arch file to decrease at least one of said dimensions and then utilizing the modified digital dental arch file to form the desired orthodontic appliance and other dental insert.

Abstract: A method and apparatus form a tooth positioner for repositioning at least one tooth of a patient and provide a dental arch cast of a patient, separate at least one tooth from the dental arch cast, fix a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstruct the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and hold the pins in a material that may be softened, soften the material, apply force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and form a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.

Abstract: A method and apparatus form a tooth positioner for repositioning at least one tooth of a patient and provide a dental arch cast of a patient, separate at least one tooth from the dental arch cast, fix a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstruct the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and hold the pins in a material that may be softened, soften the material, apply force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and form a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.

Abstract: A method for forming a tooth positioner for repositioning at least one tooth of a patient includes providing a dental arch cast of a patient, separating at least one tooth from the dental arch cast, fixing a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, heating an area to soften an area, applying force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and forming a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.

Abstract: A method for forming a tooth positioner for repositioning at least one tooth of a patient includes providing a dental arch cast of a patient, separating at least one tooth from the dental arch cast, fixing a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, heating an area to soften an area, applying force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and forming a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.

Abstract: A method for forming a tooth positioner for repositioning at least one tooth of a patient includes providing a dental arch cast of a patient, separating at least one tooth from the dental arch cast, fixing a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, heating an area to soften an area, applying force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and forming a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.

Abstract: A method for forming a tooth positioner for repositioning at least one tooth of a patient includes providing a dental arch cast of a patient, separating at least one tooth from the dental arch cast, fixing a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstructing the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patient's mouth and holding the pins in a material that may be softened by heat, heating an area to soften an area, applying force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and forming a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.