Custom Dental Aligner Moulds

The Challenge

A dental laboratory in Milan was growing rapidly and needed to scale their clear aligner production. Their in-house printer could only handle 20 moulds per day, creating a bottleneck. They needed a reliable outsourcing partner who could deliver consistent quality at volume with certified biocompatible materials.

Our Approach

We set up a dedicated SLA production workflow using biocompatible resin approved for indirect oral contact. Each mould is printed at 50-micron layer height to ensure precise tooth geometry. Automated quality checks flag any dimensional variance beyond tolerance. Moulds are cleaned, cured, and packed in sealed bags ready for thermoforming.

The Result

We now produce over 200 moulds per week for this client, with next-day shipping to their Milan lab. Rejection rate is below 0.5%. The partnership has freed up their in-house capacity for more complex orthodontic work, and they have expanded their patient volume by 40% since onboarding with us.