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Objectives <p>Balancing the aesthetic and mechanical effects remains challenging in terms of attachments. This study proposed a strategy by introducing laser surface texturing in clear aligners fabrication to enhance the retention and grip of clear aligners and minimize the size of attachments.</p> Materials and methods <p>A grid pattern with a spacing of 1&#xa0;mm on the surface of thermoplastic polyurethane substrate was textured using a CO<sub>2</sub> laser. We used LST-modified TPU to fabricate aligners and evaluated its mechanical and surface properties.</p> Results <p>TPU after laser surface texturing exhibited increased roughness, and therefore enhanced the retention and gripping force of LST-modified clear aligners. Although the average transmittance of the LST-modified TPU was 2.32% lower, LST had little negative effect on aesthetic of aligners.</p> Conclusions <p>Laser surface texturing, as a novel auxiliary approach in aligners fabrication, has the potential to enhance mechanical properties such as roughness, retention and force delivery of TPU-fabricated clear aligners.</p> Clinical relevance <p>The mechanical enhancement of LST-modified clear aligners could have a better control on teeth movements and reduce the sizes of attachments without sacrificing their mechanical effect, helping to balance the aesthetics and mechanic effects of attachments.</p>

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Properties enhancements of clear aligners after the laser surface texturing modification on thermoplastic polyurethane

  • 期刊论文

  • 发表日期：

    2025年10月11日

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  • Chao Liu,
  • Yang Li,
  • Yiwei Zhao,
  • Bowen Meng,
  • Zhuo Xie,
  • Qi Guo,
  • Yuanbo Liu,
  • Xin Chen,
  • Yang Cao

摘要

Objectives

Balancing the aesthetic and mechanical effects remains challenging in terms of attachments. This study proposed a strategy by introducing laser surface texturing in clear aligners fabrication to enhance the retention and grip of clear aligners and minimize the size of attachments.

Materials and methods

A grid pattern with a spacing of 1 mm on the surface of thermoplastic polyurethane substrate was textured using a CO2 laser. We used LST-modified TPU to fabricate aligners and evaluated its mechanical and surface properties.

Results

TPU after laser surface texturing exhibited increased roughness, and therefore enhanced the retention and gripping force of LST-modified clear aligners. Although the average transmittance of the LST-modified TPU was 2.32% lower, LST had little negative effect on aesthetic of aligners.

Conclusions

Laser surface texturing, as a novel auxiliary approach in aligners fabrication, has the potential to enhance mechanical properties such as roughness, retention and force delivery of TPU-fabricated clear aligners.

Clinical relevance

The mechanical enhancement of LST-modified clear aligners could have a better control on teeth movements and reduce the sizes of attachments without sacrificing their mechanical effect, helping to balance the aesthetics and mechanic effects of attachments.