Toothsi scaled aligner production using SLA to achieve high accuracy, stability and cost effective mass customisation.
Layer Accuracy
Arches Per Build
Stable Production
Toothsi is a leading manufacturer of invisible dental aligners. Each day, thousands of customised aligners are produced and delivered across the country, serving orthodontic patients who typically replace 25 to 40 pairs during the course of treatment.
Focused on precision, consistency and scalable customisation, Toothsi continuously invests in advanced manufacturing technologies. Since 2019, the company has implemented stereolithography solutions that support high-volume, high-resolution aligner production.
Orthodontic aligner manufacturing demands:
• High-dimensional accuracy for incremental tooth movement
• Smooth surface finish suitable for thermoforming
• Capability to produce large volumes daily
• Production stability with minimal downtime
Traditional manufacturing approaches struggled to balance full customisation with efficient mass production. Smartee required a technology capable of reliably and at scale producing high-resolution tooling.
After evaluating multiple 3D printing technologies, Toothsi selected UnionTech stereolithography equipment based on accuracy, cost-effectiveness, efficiency, stability, and safety.
The solution included:
• 0.1 mm layer thickness meeting aligner printing requirements
• Large effective build area enabling more than 100 pairs per print cycle
• Specially developed photosensitive resin
• High strength and safe production process
• Responsive after-sales service and technical support
UnionTech stereolithography systems were integrated into Toothsi’s digital workflow to produce precise tooling directly from CAD data. These tools were then used for secondary thermoforming to create the final aligners.
• End-to-end digital production from CAD to print
• Batch manufacturing using large-format SL systems
• Controlled resin processing for strength and consistency
• Ongoing maintenance support to ensure uninterrupted production
UnionTech’s open material philosophy and responsive service ensured that equipment maintenance and performance improvements were addressed promptly, safeguarding operational stability.
Toothsi achieved stable, high-volume production, printing more than 100 aligner arches in a single build with 0.1 mm precision.
The stereolithography solution delivered:
• Scalable mass customisation
• High surface quality and feature resolution
• Cost-efficient production
• Reliable daily output of thousands of aligners
With UnionTech’s integrated solution of equipment, materials, and services, Toothsi strengthened its manufacturing capacity and continued to expand its national presence in invisible aligners.
