Disclosed herein are thermoplastic and thermoset composite materials, which may be used to generate dental appliances such as dental aligners, and methods of preparation and manufacture.

Disclosed herein are thermoplastic and thermoset composite materials, which may be used to generate dental appliances such as dental aligners, and methods of preparation and manufacture.

A method includes identifying first geometry of a first mold associated with a first dental arch and a second geometry of a second mold associated with a second dental arch. The method further includes determining, based on the first geometry and the second geometry that the first mold and the second mold are to be used for simultaneous forming of a first dental appliance and a second dental appliance on a plate in a dental appliance manufacturing system. The method further includes causing, based on the first geometry and the second geometry, one or more portions of the dental appliance manufacturing system to be configured to form the first dental appliance and the second dental appliance.

An assembly useful for thermoforming a dental aligner from polymer sheet material includes (a) a custom dental model having a planar bottom surface and a receptacle formed in said planar bottom surface; and (b) a reusable die removably received in said receptacle.

An assembly useful for thermoforming a dental aligner from polymer sheet material includes (a) a custom dental model having a planar bottom surface and a receptacle formed in said planar bottom surface; and (b) a reusable die removably received in said receptacle.

A method and a system for generating an augmented 3D digital model of an intraoral anatomical structure a subject. The method comprises: obtaining an unfolded surface of a 3D digital model of the intraoral anatomical structure, the unfolded surface comprising a 2D grid including a plurality of 2D cells; generating a texture reference map by: assigning, to each one of the plurality of 2D cells, a respective value of at least one textural parameter; using the texture reference map for applying the at least one textural parameter onto the 3D digital model to generate the augmented 3D digital model; and causing display of the augmented 3D digital model of the intraoral anatomical structure.

A first appliance and a second appliance comprise engagement surfaces that provide mandibular relocation forces and forces to limit lateral movement of the jaw, such as opposing inclined surfaces on opposite sides of the mouth. In some embodiments, engagement surfaces between oral appliances comprise a curvature difference, which allows engagement at differing angles and positions.

A first appliance and a second appliance comprise engagement surfaces that provide mandibular relocation forces and forces to limit lateral movement of the jaw, such as opposing inclined surfaces on opposite sides of the mouth. In some embodiments, engagement surfaces between oral appliances comprise a curvature difference, which allows engagement at differing angles and positions.

Thermoforming methods of making orthodontic appliances and orthodontic appliances preforms employ a barrier sheet positioned between an appliance sheet and a dental model during the forming step. The thermoformed orthodontic appliances are more pellucid than appliances thermoformed without the barrier sheet.