Revolutionizing Orthodontics: The Synergy of 3D Printed Appliances and Temporary Anchorage Devices (TADs)
Author : By Dr. Ajit Kalia

The field of orthodontics has experienced a transformative revolution due to technological advancements, particularly the integration of 3D printing technology with Temporary Anchorage Devices (TADs). This has streamlined treatment processes and opened up new possibilities for customized solutions. Metal 3D printing technology is being used to produce customized orthodontic appliances, offering patient comfort, treatment efficacy, and predictability. Technological advancements in 3D printers and additive manufacturing principles have significantly impacted dentistry, with Charles Hull’s foundation laid in 1986 and Prof. Ely Sachs’ invention in 1995.

Orthodontic applications of 3D printing include stereolithography, fused deposition modeling, digital light processing, PolyJet photopolymer, and selective laser sintering (SLS). SLA, DLP, and PPP are 3D printers. SLS uses a laser to fuse powdered materials layer by layer, creating three-dimensional objects. It’s used in prototyping, end-use parts, and custom manufacturing, but faces challenges like post-processing, equipment costs, and powder handling.

3D printing technology is revolutionizing orthodontic practice by providing study models, brackets, retainers, aligners, appliances, surgical guides, simulated jaws, functional appliances, transverse correctors, distalizers, and 3D printed screws. This technology has revolutionized treatment planning, customization, and efficiency. Orthodontic treatments have undergone a significant transformation with the introduction of 3D printing, especially in the development of devices such as the MARPE (Miniscrew-assisted Rapid Palatal Expander) and MSE (Maxillary Skeletal Expander). It allows for customized device design, patient-specific models, rapid prototyping, integration of screws and mechanisms, and the use of biocompatible materials. This reduces material waste and promotes a more sustainable production process. 3D printing also aids in patient compliance by providing patient-specific markings or indicators on the expander. Additionally, 3D printing enables post-production adjustments, ensuring a more patient-friendly treatment process. Overall, 3D printing demonstrates how technology can be used to tailor orthodontic treatments to individual patient needs, improving precision, comfort, and overall treatment outcomes.

In orthodontics, 3D printing facilitates the creation of diverse appliances for different types of tooth movement. Notably, it excels in orthodontic alignment, utilizing 3D-printed aligners with sequential tray adjustments to guide teeth progressively into proper alignment. The technology extends precise control to rotations and torque through customized brackets and archwires, ensuring optimal occlusion and aesthetic enhancement. Customized braces, produced via 3D printing, effectively control vertical movements like tooth intrusion and extrusion, maintaining proper occlusion, particularly during tooth extraction. This technology also aids in midline correction, guiding teeth toward the desired position for overall symmetry, especially beneficial in cases of tooth extraction. Furthermore, 3D printing plays a vital role in transverse expansion, exemplified by appliances like MARPE, applying controlled lateral forces to address issues such as crossbites and crowding. The versatility of 3D-printed orthodontic appliances spans alignment, torque control, vertical adjustments, midline correction, and transverse expansion, enhancing precision and customization for more effective and predictable orthodontic treatments.

3D-printed appliances improve treatment outcomes by enhancing predictability through customization, digital treatment planning, better fit and comfort, and iterative design and prototyping. These appliances are tailored to each patient’s unique anatomy, ensuring precise tooth movement. Digital treatment planning software allows for realistic expectations, while 3D-printed appliances reduce discomfort and enhance patient compliance. Rapid prototyping capabilities allow for iterative design adjustments based on treatment progress, ensuring better predictability throughout the treatment.

MARPE (Miniscrew-assisted Rapid Palatal Expander) and MSE (Maxillary Skeletal Expander) are examples of 3D-printed orthodontic appliances that offer a range of movements and contribute to precise and predictable orthodontic treatments. These devices, specifically designed for maxillary expansion, benefit from 3D printing for customization, integrating miniscrews and other components directly into the design. Overall, 3D printing technology contributes to precise and predictable orthodontic treatments in orthodontics. TAD-borne appliances, designed and manufactured digitally, offer precise mini-implant placement and reduce screw overloading. 3D printed appliances and TADs enhance orthodontic treatment planning, while ethical considerations include affordability, accessibility, and informed consent. Orthodontics uses 4D Facial Dynamics to understand soft tissue mobility, anatomical motion, and facial expressions, which could be crucial for orthodontic diagnosis, craniofacial abnormality, virtual surgical planning, and treatment outcomes.

The fusion of 3D printing technology with Temporary Anchorage Devices represents a paradigm shift in orthodontic care. The personalized nature of 3D printed appliances, coupled with the precision and stability offered by TADs, has revolutionized treatment approaches and outcomes. As technology continues to advance, the future of orthodontics holds exciting possibilities, promising even greater customization, efficiency, and patient satisfaction. The synergy of 3D printed appliances and TADs not only exemplifies the transformative power of innovation but also signifies a new era in orthodontic excellence.

Dr.Abhisek Ghosh did his graduation from Ragas Dental College, Chennai and post-graduation in Orthodontics from the Manipal College of Dental Sciences, Mangalore, as the best outgoing student (Gold Medalist). He is a diplomate of the Indian Board of Orthodontics and has the unique distinction of having a fellowship from all four Royal College of Surgeons-Edinburgh, England, Ireland and Glasgow.

He is the recipient of the Best Clinical Paper Award 5 times at the 47th, 48th, 49th, 53rd and 56th Indian Orthodontic Conference in Delhi, Ahmedabad, Kolkata Kochi and Pune. He is the winner of the George Jacob Award for excellence in clinical innovation presented by the Indian Orthodontic Society for the year, 2014. He has also been selected for the recently introduced IOS Exchange program to the University of Western Australia, Perth for the year 2017.

He is peer reviewer for the Journal of Indian Orthodontic Society. He is one of the key opinion leaders for ORMCO India pvt.ltd and a regular invited speaker in the national and international forum. He is a fellow of The World Federation of Orthodontist, The American Association of Orthodontist and certified in Lingual orthodontics (Incognito) and clear aligner technology (Invisalign).

He holds the post of Visiting Professor, at the Sri Ramachandra Dental College and Hospital, Chennai and is also the Chief Consultant Orthodontist at Apollo Clinics and the director of Great Lakes Orthodontic Care, Kolkata.


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Dr. Adith Venugopal is a specialist orthodontist currently working as a Senior Lecturer, Orthodontics in the Faculty of Dentistry at the University of Otago, New Zealand. He is also an adjunct associate professor and clinical instructor of orthodontics and dentofacial orthopaedics at the University of Puthisastra, Phnom Penh, Cambodia. Dr Adith Venugopal was previously in a private practice at Pachem Dental Hospital, Phnom Penh, where he practiced exclusive labial, lingual, and aligner therapy.

Dr. Adith Venugopal has completed his Ph.D. in Orthodontics from Kyungpook National University, South Korea, under the eminent Prof. Hee-Moon Kyung. He has completed his clinical M.S. with an Outstanding Graduate Student Award in Orthodontics from the University of the East Manila (2014). He earned a bachelor’s degree in dentistry (B.D.S.) (Honours) from Rajiv Gandhi University of Health Sciences, India.

He has published several scientific studies and clinical reports in international peer-reviewed scientific journals and has been an invited keynote speaker at many orthodontic congresses. He has held courses and workshops on TAD-based biomechanics all around the globe to reach high standards in clinical, research, and teaching skills. He is an associate editor for the Seminars in Orthodontics, a contributing editor for the Journal of Clinical Orthodontics, a co-editor for the Kieferorthopadie, and an assistant editor for the APOS trends in Orthodontics.

He is currently the youngest fellow of two prestigious institutions, namely the International College of Dentists & the Pierre Fauchard Academy. He is also a fellow and member of the Royal College of Surgeons of England, Glasgow, and Edinburgh. His current clinical interests are in Class III treatments, gummy smiles, intrusion biomechanics, iatrogenics, and orthodontic re-treatment.


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Dr Arun Nayak is an affable, highly-skilled orthodontist practicing exclusive orthodontics with a huge focus on providing genuine advice for the past 19 years. He has had a brilliant academic career and has been trained in one of India’s best orthodontic departments at the Government Dental College, Nagpur. He attends global summits to keep abreast with the latest developments in his field. He has been the KOL for Invisalign for past 8 years.

Dr Nayak is one of the foremost providers of Invisalign system in India. His paper on the G6 protocol has been awarded the Ashima Valiathan Best Clinical Paper at the Indian Orthodontic Conference in 2017. In addition, his paper on managing- Maxillary Deficient Class III with aligners won 2nd best case at the 2022 Indian Orthodontic Society Case Symposium.

Dr Nayak holds cases in the Align Global Gallery. He is the first and only orthodontist from India to be invited to the Invisalign Top 300 Global Forum at Vancouver in 2023. He has mentored scores of orthodontists all over India through hugely popular and intensely-scientific national study clubs.

Dr Nayak is a Platinum-Elite provider and a proud owner of the iTero scanner. He is a Diplomate of the Indian Board of Orthodontics


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Dr. Ajit Kalia is currently Professor & Chair at Department of Orthodontics- M.A. Rangoonwala
College of Dental Sciences and Research Center, Pune India. He is a post-graduate teacher and has 22-years of active teaching experience.

He completed his MDS from Ragas Dental College, Chennai under the guidance of Dr. N. R. Krishnaswamy. He is a “Diplomate of the Indian Board of Orthodontics” and is currently serving as the Director of Indian Board of Orthodontics. He has been awarded M.Orth RCS from Glasgow and M.Orth RCS from England.

Dr. Ajit Kalia has 3 patents to his credit. He is an astute clinician and academician who has keen interest in temporary anchorage device, micro esthetics and LASERs. Skeletal anchorage is his special field of interest. He has completed mini residency program on Temporary Anchorage Devices from Yonsei University in Seoul, Korea. He has attended residency program on IZC and Buccal Shelf Implant conducted by Dr. Chris Chang at Beethoven Orthodontic Center and Newton’s A Inc. in Hsinchu, Taiwan.

Dr. Ajit Kalia also had the opportunity to learn the biomechanics of miniplates and Sendai Surgery First Approach- under the supervision of Dr. Junji Sugawara at the Sendai Aoba Clinic, Japan. He has lectured at various national and international conferences and has several publications in national & international journals.

He has won the best clinical paper award at the national conference of Indian orthodontic society at 4 consecutive occasions. He received the best clinical paper award at the World Implant orthodontic conference 2022, Brazil.

He has completed MSc in Aligner Orthodontics- Level 2 from University of Turin, Italy


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Dr. Rajaganesh Gautam is a board-certified orthodontist with a private practice restricted exclusively to Orthodontics in Pune, India since the last 21 years. He completed his BDS (Bachelor of Dental Surgery) from Government Dental College and Hospital, Mumbai in 2000 and completed his MDS (Masters in Dental Surgery) in Orthodontics from Manipal College of Dental Sciences, Mangalore in 2002. He has completed international Mini Residency programs in advanced Orthodontics at the Yonsei University, Seoul and Kyungpook National University, Daegu, South Korea and at the Taipeh Medical University, Taipeh, Taiwan.

He is a Diplomate of National Board (DNB) and a Diplomate of the Indian Board of Orthodontics. He is presently Professor and Head of Department, Department of Orthodontics, Dr. D.Y. Patil Dental College and Hospital, Pimpri, Pune and is the Chairman of the Indian Board of Orthodontics.
He has authored publications in both national and international journals and is on the board of reviewers for many of these journals. He has conducted national workshops related to the use of TADs in orthodontics.

He has been an invited keynote and guest speaker at the Indian Orthodontic Society national conferences, post-graduate student conventions and at various national and international orthodontic forums. His clinical and research interests include aligner orthodontics, temporary anchorage devices, orthodontic resolution of impacted teeth, adult/ interdisciplinary treatment, and biological mechanisms related to orthodontic tooth movement.


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