Design, numerical simulation, and in vitro examination of a CAD/CAM-fabricated active orthodontic treatment element.

The article focuses on the design, numerical simulation, and in vitro evaluation of individually constructed, computer-aided design/computer-aided manufacturing (CAD/CAM) fabricated active orthodontic power chains. Using finite element analysis (FEA) and 3D printing with thermoplastic polyurethane (TPU) and thermoplastic elastomer (TPE) filaments, the study demonstrated that these customized elastic chains can reproducibly generate predefined forces suitable for orthodontic tooth movement, with measured forces ranging from 196 to 681 grams and a high correlation (R = 0.91 to 0.98) between simulated and experimental results. A custom-built, high-precision measuring device validated the force measurements, showing excellent reliability. The findings suggest that integrating CAD/CAM technology, numerical simulation, and additive manufacturing could enable patient-specific, force-driven orthodontic treatment planning, potentially reducing treatment time and side effects such as root resorption.