How to Design Clear Aligners in Maestro 3D Dental Studio Expert v7

Designing clear orthodontic aligners with Maestro 3D Dental Studio Expert is a streamlined process that takes you from digital impressions to 3D-printed models in just a few steps. The software provides a complete digital aligner workflow that is both accurate and efficient.

🦷 Step-by-Step Aligner Design Workflow

1️⃣ Import Patient Scans

• Import the intraoral or desktop scanner STL/PLY files directly into Maestro 3D.
  
  

• The software automatically detects and aligns the upper and lower jaws.
  
  

• Verify the scan quality to ensure accurate aligner design.
  
  

2️⃣ Automatic Tooth Segmentation

• Use Maestro’s AI-powered segmentation tool to automatically separate each tooth.
  
  

• The system assigns tooth numbering and generates margin lines with minimal manual input.
  
  

• Adjust the segmentation if needed to improve precision.
  
  

3️⃣ Initial Alignment & Virtual Setup

• Create a digital orthodontic setup by moving teeth into the desired final position.
  
  

• The software allows control over tip, torque, rotation, and translation.
  
  

• You can define the center of rotation and apply constraints for realistic movements.
  
  

4️⃣ Treatment Staging (Step Division)

• Maestro automatically divides the treatment into sequential stages based on your defined movement limits (e.g., 0.25–0.3 mm per aligner).
  
  

• Each stage corresponds to a separate aligner that progressively moves the teeth.
  
  

• You can preview the treatment animation to confirm movement efficiency.
  
  

5️⃣ Model Builder & Attachments

• Add attachments or engagers directly to the teeth where extra grip is needed.
  
  

• Use the Model Builder module to generate aligner models for each treatment stage.
  
  

• Apply the Hollow Export Option to save resin/material during 3D printing.
  
  

6️⃣ 3D Printing Preparation

• Export the staged models in STL format.
  
  

• The files are fully compatible with most 3D printers and printing software.
  
  

• Print the models and thermoform the clear aligners on top of them.
  
  

🎯 Why Maestro 3D for Aligner Design?

• Fully integrated digital workflow from scan → aligner → print.
  
  

• Automatic staging for fast treatment planning.
  
  

• Real-root CBCT integration (unique to Maestro) for anatomical precision.
  
  

• Saves time and materials with hollow model export.
  
  

📈 

• How to design aligners in Maestro 3D Dental Studio
  
  

• Maestro aligner workflow
  
  

• Digital orthodontic aligner design software
  
  

• Step-by-step aligner creation
  
  

• Aligner staging in dental CAD software
  
  

• 3D printing dental aligner models
  
  

• Orthodontic treatment planning software