Biomechanical Insights into the Variation of Maxillary Arch Dimension with Clear Aligners: A Finite Element Analysis-Based Scoping Review

Clear aligners (CAs) have emerged as a widely accepted alternative to conventional fixed orthodontic appliances due to their aesthetic appeal, comfort, and removability. Despite their increasing use, the precise biomechanical behavior of CAs—particularly in relation to maxillary arch expansion and torque control—remains incompletely understood. This scoping review aims to synthesize and critically examine the recent body of evidence derived from finite element analysis (FEA) studies investigating the performance of clear aligners in managing transverse discrepancies and controlling tooth movement. It considered studies published up to April 2025. All included FEA studies assumed dental and bone tissues as linearly elastic, homogeneous, and isotropic, unless otherwise specified. Five in silico studies were included, all employing three-dimensional FEA models to assess the influence of various clinical and design parameters, such as aligner thickness, movement sequence, attachment configuration, and torque compensation. The findings consistently show that movement protocols involving alternating activation patterns and specific attachment designs can significantly improve the efficiency of maxillary expansion, while reducing undesired tipping or anchorage loss. Additionally, greater aligner thicknesses were generally associated with increased force delivery and more pronounced tooth displacement. Although FEA provides a powerful tool for visualizing stress distribution and predicting mechanical responses under controlled conditions, the lack of standardized force application and limited clinical validation remain important limitations. These findings underscore the potential of optimized aligner protocols to enhance treatment outcomes, but they also highlight the need for complementary in vivo studies to confirm their clinical relevance and guide evidence-based practice.