What Clear Moves Aligners Are Made Of: Materials & Manufacturing

clear aligner manufacturing setup

When it comes to orthodontic treatment, not all clear aligners are created equal. At Clear Moves Aligners, the difference lies in the materials we use and the precision manufacturing process behind every aligner. This ensures not only a beautiful smile but also comfort, safety, and predictable results.


Premium Materials: The Core of Every Aligner

Clear Moves Aligners are crafted from high-grade, medical-grade thermoplastic sheets and polymers that are engineered for strength, clarity, and patient comfort. Some of the premium materials we use include:

  • Essix sheets – Renowned for their durability and crystal-clear transparency.

  • Zendura FLX – A flexible yet strong material that offers comfort without compromising performance.

  • TPU 3-Layer FLX sheets – Advanced multilayer technology combining flexibility, resilience, and stain resistance.

These materials are specifically chosen to provide:

  • Long-lasting transparency, keeping your aligners invisible.

  • Optimal flexibility for comfortable wear and easy removal.

  • Consistent strength to move teeth effectively.

  • Biocompatibility and safety for long-term use inside the mouth.


Step-by-Step Manufacturing Process

Creating a Clear Moves Aligner is a blend of advanced technology and careful craftsmanship. Here’s how each aligner is made:

1. Consultation & Digital Data Collection

Treatment begins with a detailed clinical assessment. Digital intraoral scans, photographs, and X-rays are taken to capture a precise model of the patient’s teeth and bite.

2. Digital Treatment Planning

Using 3D orthodontic software, every stage of tooth movement is mapped out. This step-by-step plan is reviewed by dental professionals to ensure accuracy and predictability.

3. 3D Model Printing

Once approved, 3D printers create physical models of each treatment stage. These models serve as the foundation for thermoforming the aligners.

4. Thermoforming the Aligner

  • A premium thermoplastic sheet is heated until pliable.

  • It is then pressure- or vacuum-formed over the 3D model, ensuring an exact fit.

  • After cooling, the sheet takes on the precise shape of the teeth at that stage of treatment.

5. Finishing Touches

Every aligner is hand-finished to remove sharp edges, polished for smoothness, and laser-marked with identification codes for easy tracking.

6. Quality Control & Disinfection

Each aligner undergoes strict quality checks for strength, clarity, and accuracy. They are disinfected before packaging to ensure hygiene and safety.

7. Packaging & Delivery

Aligners are packaged securely — with options for branded, white-label packaging for clinics — and shipped directly to dental professionals or treatment providers.


Certifications & Safety Standards

Clear Moves Aligners are produced in compliance with international standards and certifications, including FDA, ISO, and CE. This ensures patients and providers can trust the safety, performance, and reliability of every aligner.


Why It Matters

The choice of material and the precision of the manufacturing process make all the difference in aligner treatment. With Clear Moves Aligners, patients enjoy:

  • Superior comfort from smooth edges and flexible materials.

  • Discreet wear thanks to stain-resistant transparency.

  • Predictable results supported by digital planning and professional oversight.

  • Trusted safety through rigorous testing and certified materials.


Final Thoughts

Clear Moves Aligners are not just plastic trays — they are the result of cutting-edge technology, medical-grade materials, and careful craftsmanship. By combining digital treatment planning, 3D printing, thermoforming, and rigorous quality control, we deliver aligners that dentists trust and patients love.

With Clear Moves, every smile is built on innovation, safety, and comfort.