Biomechanics of directly 3D-printed clear aligners for vertical and sagittal correction

Directly 3D-printed clear aligners (DPAs) represent an emerging orthodontic treatment modality enabled by advances in photopolymer material science and additive manufacturing. Current clinical applications of DPAs are in their primary stage and largely rely on standard-shaped aligners without custom design modifications. In this case, a deep bite malocclusion in a 38-year-old male patient with multiple crown restorations, a premolar scissor bite, a midline discrepancy, and a half-cusp Class III molar relationship was successfully treated using design-modified DPAs. The design modifications included integrated anterior bite blocks intended to influence incisor intrusion and inclination, selectively exposed occlusal coverage to minimize unwanted posterior intrusion, and strategic undercut block-outs to enhance posterior distalization. As a preliminary clinical demonstration, this case illustrates the potential of design-modified DPAs for the management of deep bite malocclusions. Further studies are needed to optimize clinical protocols and validate the biomechanical advantages of DPAs, thereby advancing aligner therapy and digital orthodontics.