Tech, ExplainedIndustrial tech and mobility
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Mass customisation with 3D printing

A million items, each one different.

INSIDE: 3D PRINTERHOW IT WORKS · CLEAR ALIGNERS FOR ONE PATIENTThe dentistscans thepatient's teethin the clinicSoftware plansthe toothmovement in20 stagesA 3D printerprints a mouldfor each stage,40 for the upperand lower teethA plastic sheetis pressed overeach mould andtrimmed to makethe trayThe trays arelabelled bystage and sentto the dentistThe patientwears eachpair of traysfor one or twoweeks, in orderINSIDE: 3D PRINTERHOW IT WORKS · CLEAR ALIGNERS FOR ONE PATIENTThe dentist scansthe patient'steeth in the clinicSoftware plans the toothmovement in 20 stagesA 3D printer printsa mould for eachstage, 40 for theupper and lower teethA plastic sheet ispressed over eachmould and trimmedto make the trayThe trays arelabelled by stage andsent to the dentistThe patient wears eachpair of trays for one ortwo weeks, in orderINSIDE: 3D PRINTER · CLEARALIGNERS FOR ONE PATIENTThe dentist scans the patient's teeth inthe clinic↓Software plans the toothmovement in 20 stages↓A 3D printer prints a mould for eachstage, 40 for the upper and lower teeth↓A plastic sheet is pressed over eachmould and trimmed to make the tray↓The trays are labelled by stage and sentto the dentist↓The patient wears each pair of trays forone or two weeks, in order
A patient's teeth are scanned and planned in stages, a mould for each stage is 3D printed, plastic trays are formed over the moulds, and the trays are sent to the dentist.
opens a page inside this one a page in the same scene a page in another scene a concept page a label only, with no page

Mass customisation with 3D printing is production in which every item is different from the next, yet the items are made in very large numbers. The best-known example is clear aligners, the transparent plastic trays that move a person's teeth into place. Each set is made to fit one patient, and the maker produces them by the million.

Mass production makes millions of identical items, for example with injection moulding. Its mould is expensive, so it pays only if the same part is made in great numbers. A 3D printer needs no mould. It can print a different shape every time, from a new file. So a factory can print thousands of different shapes a day, with no extra tooling cost.

The process needs software at every step. The dentist scans the patient's teeth, and the scan becomes a 3D model, as with clear aligners and tooth scanners. Software plans how each tooth should move, in small stages. For each stage, a mould of the teeth is printed. A sheet of plastic is pressed over it and trimmed to make that stage's aligner. The trays are labelled, packed and sent to the dentist. Dental crowns, which are milled and printed to order, follow the same idea.

The same idea applies to other things made to fit the body. Imagine a maker of shoe insoles in Nagpur for people with diabetes, whose feet need an exact fit. A clinic scans each patient's feet. Software shapes an insole to match, and a printer prints that pair in a few hours. The next patient's pair has a different shape, and it costs the maker no new tooling.

This is a very large use of 3D printing, and it depends on automation. Nobody can plan millions of unique items by hand. The model of each item is drawn from the scan by software similar to CAD, with little or no human work for each item.

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