Primary process: Thermoforming. The full route, materials, tolerances and design tips for a clear aligner, with an indicative cost.
ThermoformingPrimary process
PolymerFamily
6Route steps
+/-0.3mmTypical tol.
A clear aligner is primarily made by Thermoforming. Thermoforming heats a plastic sheet until pliable and draws it over a mould with vacuum or pressure, trimming the formed part from the sheet. Below is the full route to make a clear aligner, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a clear aligner is made
The usual route, raw material to finished part. The amber step is where the clear aligner gets its basic shape.
Material
Select the plastic sheet grade and gauge for the clear aligner.
Thermoforming
Heat the sheet and draw it over the mould to make the clear aligner.
Tooling Low to medium Tolerance ±0.3 to 1.5mm Lead 2 to 8 weeks
Trim
Trim the edges, flash and any waste material.
Secondary
Where the clear aligner needs them, add inserts, printed graphics or machined details.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Assembly
Where the clear aligner joins other parts, snap-fit, weld or bond it into the finished product.
Tooling Low Tolerance good Lead immediate
Inspection
Check fit, finish and any functional dimensions.
Need the real cost for a clear aligner? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a clear aligner
Grade
Why it suits this
ABS/HIPS sheet
Easy to form
PETG
Clear, tough
Polycarbonate
Impact, clarity
Design
Design tips
General pointers. The full design-for-manufacturing list for a clear aligner is in the dossier.
Deep draw with sharp corners.Add draft + radii.
Tight tolerance expected.Design loose; it's a forming process.
Cost
What a clear aligner should cost
Trays, panels, packaging from heated sheet; low tooling, great for large light parts at low-to-mid volume.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a clear aligner at your volume, in your currency, are in the dossier.
MODEL EST.
$29 to 82per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
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Everything you need to quote and source it
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Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
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A clear aligner is primarily made by thermoforming. The route is: Material; Thermoforming; Trim; Secondary; Assembly; Inspection.
What does a clear aligner cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $29 to 82 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a clear aligner made from?
Common choices are ABS/HIPS sheet; PETG; Polycarbonate.
What is the main process for a clear aligner?
Thermoforming. Trays, blisters, panels, clamshells and aligners at low to medium tooling cost.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
