Assessment of predicted software outcome and actual clinical outcome to evaluate tooth movement efficacy with clear aligners

Objectives: This study aimed to compare predicted tooth movement outcomes generated by aligner software with actual clinical outcomes following aligner therapy. Methods: Ten patients with mild to moderate anterior malalignment treated using in-house aligner therapy were included. Predicted software-generated STL models were superimposed on post-treatment clinical models using MeshLab software. Tooth movement accuracy was evaluated across three spatial planes. Results: Mesiodistal movements showed the highest predictability, followed by buccolingual and vertical movements. Anterior teeth demonstrated greater accuracy compared to posterior segments. Torque and intrusion movements were least predictable. Conclusions: Predicted aligner software models do not fully replicate achieved clinical outcomes. Planned overcorrections are necessary to compensate for biological variability and manufacturing limitations inherent to aligner therapy.