Vol. 11, Issue 4, Part G (2025)

Introduction: Digitally aligned orthodontics has evolved significantly with the incorporation of digital workflows and 3D printing technologies, enabling for more accurate planning and more controlled manufacturing of clear aligners.

Objective: To analyze recent scientific evidence on technological advances, the accuracy of digital setups and the application of 3D printing in the manufacture of transparent aligners in orthodontics.

Methodology: A search for literature articles published in the last five years in PubMed, Scopus, ScienceDirect and Google Scholar was conducted. Terms such as "Clear Aligners", "Digital Orthodontics", "3D Printing" and "Virtual Setup" were used. We included in vitro experimental studies, comparative studies, and clinical studies that evaluated tooth movement accuracy, mechanical properties of materials, and digital workflows.

Results: Evidence indicates that directly 3D printed aligners exhibit greater geometric accuracy and better thickness control than thermoformed aligners, with three-dimensional deviations below 0.2 mm in vitro studies. Digital planning allows staged movements of 0.2-0.3 mm and rotations of 1-3°, although predictability is lower for complex movements, such as rotations and extrusions.

Conclusion: Digitally aligned orthodontics supported by 3D printing is an effective and promising tool; however, its clinical success depends on rigorous planning, proper material selection, and mastery of digital flow.