Does thermoforming setup affect thickness in thermoplastic orthodontic appliances? A comparison of single vs. dual-model fabrication

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dc.authorid0009-0005-3767-7415
dc.authorid0009-0004-4992-4092
dc.authorid0009-0008-8331-9493
dc.authorid0009-0004-6316-6072
dc.contributor.authorAllaf, Ferdi
dc.contributor.authorArslan, Meriç
dc.contributor.authorÖzcan, Mustafa
dc.contributor.authorErdem, Buket
dc.date.accessioned2026-08-25T12:06:47Z
dc.date.available2026-08-25T12:06:47Z
dc.date.issued2026
dc.departmentFakülteler, Diş Hekimliği Fakültesi, Klinik Bilimler Bölümü, Ortodonti Ana Bilim Dalı
dc.description.abstractThermoforming remains the predominant fabrication route for clear thermoplastic orthodontic appliances, yet it reduces and redistributes sheet thickness, which governs force delivered to teeth. Simultaneous thermoforming of two models may reduce fabrication time and material waste; however, its effect on final appliance thickness has not been evaluated. This in vitro study compared appliance thickness after thermoforming over a single model or two models simultaneously, using ten commercial aligner brands with different polymer composition and initial thickness. Thickness was measured with a digital caliper at anterior, canine and posterior sites, and analyzed using three-way ANOVA with Tukey post hoc tests. A significant three-way interaction (measurement point × number of models × brand; p < 0.001) was found. Significant single- versus dual-model differences emerged in some brand–region combinations; in most, dual-model appliances were thicker than single-model appliances. Four brands showed no significant difference at any site. Within the limits of this study, simultaneous fabrication of two appliances in a single thermoforming cycle produced appliances with thicknesses comparable to, and often slightly greater than, those fabricated over a single model. Simultaneous thermoforming maintained comparable appliance thickness and may improve manufacturing efficiency.
dc.identifier.citationAllaf, F., Arslan, M., Özcan, M., & Erdem, B. (2026). Does thermoforming setup affect thickness in thermoplastic orthodontic appliances? A comparison of single vs. dual-model fabrication. Polymers, 18(15), pp. 1-12. https://doi.org/10.3390/polym18151909
dc.identifier.doi10.3390/polym18151909
dc.identifier.endpage12
dc.identifier.issn2073-4360
dc.identifier.issue15
dc.identifier.pmidPMID: 42589838
dc.identifier.scopus2-s2.0-105047175781
dc.identifier.scopusqualityQ1
dc.identifier.startpage1
dc.identifier.urihttps://doi.org/10.3390/polym18151909
dc.identifier.urihttps://hdl.handle.net/20.500.13055/1601
dc.identifier.volume18
dc.identifier.wosWOS:001847868600001
dc.identifier.wosqualityQ1
dc.indekslendigikaynakPubMed
dc.indekslendigikaynakWeb of Science
dc.indekslendigikaynakScopus
dc.indekslendigikaynak.otherSCI-E - Science Citation Index Expanded
dc.institutionauthorAllaf, Ferdi
dc.institutionauthorArslan, Meriç
dc.institutionauthorÖzcan, Mustafa
dc.institutionauthorErdem, Buket
dc.institutionauthorid0009-0005-3767-7415
dc.institutionauthorid0009-0004-4992-4092
dc.institutionauthorid0009-0008-8331-9493
dc.institutionauthorid0009-0004-6316-6072
dc.language.isoen
dc.publisherMDPI Publishing
dc.relation.ispartofPolymers
dc.relation.publicationcategoryMakale - Uluslararası Hakemli Dergi - Kurum Öğretim Elemanı
dc.rightsinfo:eu-repo/semantics/openAccess
dc.subjectClear Aligner
dc.subjectThermoforming
dc.subjectThermoplastic
dc.subjectAligner Thickness
dc.subjectPET-G
dc.titleDoes thermoforming setup affect thickness in thermoplastic orthodontic appliances? A comparison of single vs. dual-model fabrication
dc.typeArticle
dspace.entity.typePublication

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