Conformal Iontronic Sensing Clear Aligner

Abstract The clear aligner, commonly utilized in orthodontic treatment for malocclusion, necessitates the quantification of orthodontic forces, which is highly demanded by doctors for enhancing risk management and treatment efficiency. However, the current technology still faces obstacles in achieving conformal integration of pressure sensors onto clear aligners with large curvature for the quantification and real‐time monitoring of orthodontic forces. In this paper, a conformal iontronic sensing clear aligner (CSA) is proposed based on flexible iontronic sensing mechanism, which conformally integrates the sensor with the aligner to quantify orthodontic forces throughout the treatment process while preserving the aligner's original function. Specifically, the ionic coating is seamlessly integrated onto the diaphragm by applying a layer of ionic paint before molding the clear aligner, while the sensing electrode array, designed using a kirigami‐based structure, is seamlessly adhered to the ionic coating. By integrating the CSA into a dental model, its exceptional sensitivity and precise pressure mapping capabilities have been demonstrated. This enables the identification of various tooth movement patterns, discernment of orthodontic force magnitude, and continuous monitoring of forces throughout the orthodontic treatment. Consequently, this research is expected to significantly advance risk management, outcome prediction, and treatment efficiency in orthodontic treatments.