Conformal Iontronic Sensing Clear Aligner

Clear aligners currently lack the ability to provide biomechanical data, which limits precise clinical adjustments. To address this, we developed a novel conformal iontronic sensing clear aligner (CSA) that simultaneously corrects tooth misalignment and measures orthodontic forces in real time. A flexible ionic coating was applied to the aligner diaphragm before molding, and a kirigami-based electrode array was seamlessly integrated with the coating. This innovative design harnesses the iontronic sensing mechanism to deliver high sensitivity and accurate pressure mapping on complex curved surfaces. Mechanical properties—including sensitivity, linearity, and minimal pressure resolution—were rigorously characterized using calibrated force application and precise capacitance measurements. Dental models were employed to simulate various tooth movement patterns, replicating clinical conditions and validating the system’s performance. The CSA demonstrated a sensitivity of 1.73 nF kPa⁻¹ cm⁻², a broad detection range of 0–40 kPa with excellent linearity (R² = 0.998), and a minimal pressure resolution of 6 Pa. It reliably detected subtle variations in orthodontic forces corresponding to rotational, bodily, and vertical tooth movements, confirming its capability for dynamic force quantification and precise mapping of force distribution. By integrating iontronic sensing into clear aligners, this work offers a breakthrough solution for simultaneous tooth correction and force monitoring, paving the way for personalized, data-driven orthodontic treatment.