Expansion rebound deformation of clear aligners and its biomechanical influence: a three-dimensional morphologic analysis and finite element analysis study.

Objectives: To determine the expansion rebound deformation (ERD) of clear aligners (CAs) and its biomechanical influence.

Materials and methods: A four-premolar extraction treatment plan was carried out for a patient with 2 CA companies. Thirty-six digitally scanned clear aligners with the corresponding 36 virtually constructed "ideal" aligners were constructed. The arch width and length between pairs of reference landmarks of the scanned CAs and corresponding dentition models were measured. Cone-beam computed tomography data and digital dental models were used for three-dimensional (3D) finite element analysis (FEA) modeling. Thirty-six scanned CA models with the corresponding 36 ideal CA models were constructed. One-way analysis of variance was used to determine the differences among deviation values at tooth level, and paired t-test was used to compare the displacements of teeth between the two group of CAs.

Results: All CAs were wider and shorter than the digital model from which they were constructed. In the scanned CA model group, significant stress was observed in the buccolingual area of the periodontal ligament on posterior teeth, and the corresponding displacements of teeth were also noted. Significantly larger coronal displacements were noted for the lateral incisor, the canine, the second premolar, and the first molar in the scanned CA group (P < .05).

Conclusions: The general trend of ERD of thermoformed CAs was shown. This deformation may cause unforeseen tooth movements and negatively affect treatment outcomes.