All-in-one Automated Clear Aligner Machine (Film Sheet) – 120 Aligners/Hour

Product Introduction

All-in-one Automated Clear Aligner Machine (Film Sheet) – 120 Aligners/Hour is an automated production machine developed for dental invisible orthodontic applications. It integrates automatic teeth mold feeding, thermoforming, laser marking, and precision trimming into one production system.

With a capacity of up to 120 aligners per hour and a working cycle of about 30 seconds per piece, the machine is designed for efficient and consistent clear aligner manufacturing. Its flexible film-sheet system supports different film shapes, thicknesses, and brands, making it suitable for medium-scale manufacturers handling small batches and multiple product varieties.

Main Features

1. 120 Aligners/Hour Production Capacity

The upgraded system increases production efficiency from 80 pcs/hour to 120 pcs/hour, with an operating efficiency of approximately 30 seconds per piece. It is suitable for continuous production and growing clear aligner manufacturing operations.

2. Multi-Film Sheet Compatibility

The automatic feeder supports three film sheet models and can work with different film specifications, thicknesses, and brands. Standard film sizes include 125 mm round and 105 mm square sheets, while customized sizes can also be supported.

This flexible configuration is suitable for manufacturers producing multiple clear aligner models in small or medium batches.

3. Automatic Teeth Mold Feeding

The machine automatically loads dental molds and uses visual recognition to identify and accurately position them on the tooling.

The feeding system accommodates 4 × 24 molds, with a total capacity of 96 pieces, allowing approximately one hour of continuous unattended operation under specified conditions.

4. High-Pressure Thermoforming

The thermoforming unit evenly heats and softens the film before forming it over the dental mold. The temperature is adjustable from 0–700°C according to material and process requirements.

The controlled thermoforming process helps produce clear aligner prototypes with consistent forming and fitting characteristics.

5. High-Precision Robotic Trimming

The system uses an ABB 6-axis robot for automated trimming. Its flexible multi-axis movement is suitable for complex, irregular, and curved aligner shapes.

The robot provides repeated positioning accuracy of 0.02 mm, while the specified edge consistency is below 0.3 mm.

6. Automatic Laser Marking

The integrated laser marker supports:

• Numbers

• Letters

• Barcodes

• QR codes

• Logos

This function can be used for product identification and production traceability.

7. Flexible Trimming Options

Blade trimming is available as a standard configuration, while laser trimming can be selected as an optional function according to production requirements.

Automated Production Process

All-in-one Automated Clear Aligner Machine (Film Sheet) – 120 Aligners/Hour integrates the main processing steps into one automated workflow:

1. Automatic film sheet feeding

2. Automatic dental mold feeding

3. Visual mold recognition and positioning

4. High-pressure thermoforming

5. Laser marking

6. Robotic precision trimming

7. Finished clear aligner output

The integrated workflow reduces repetitive manual operations and helps improve production consistency.

Technical Specifications

Film Sheet Application

The machine is designed for manufacturers that require flexible film-sheet production. It supports three film sheet models and can accommodate different materials and specifications.

Supported options include:

• 125 mm round film sheets

• 105 mm square film sheets

• Customized film sheet sizes

• Different film thicknesses

• Different film brands

This makes the equipment suitable for small-batch and multi-variety clear aligner manufacturing.

Automatic Mold Feeding System

The automatic teeth mold feeder uses visual recognition technology to identify and position dental molds accurately. The specified visual recognition rate is above 98%.

Four mold boxes can accommodate 96 molds in total, reducing the frequency of manual loading and supporting continuous automated production.

Robotic Trimming System

The ABB 6-axis robotic module provides flexible movement for trimming complex and curved aligner contours.

Robot specifications:

• ABB 6-axis robot

• 703 mm arm span

• 54 kg weight

• 7 kg payload

• 0.39 kW power

• 0.02 mm repeated positioning accuracy

The 800W water-cooled spindle operates at speeds below 40,000 r/min and works with the robotic system for automated trimming.

Production Quality

The automated system is designed to provide consistent processing results across production batches. Key performance indicators include:

• Visual recognition rate: >98%

• Edge consistency: <0.3 mm

• Raw edge rate: <2%

• Cut defect rate: <1%

• Robot positioning accuracy: 0.02 mm

New Generation Improvements

The new generation increases production capacity while adding automatic teeth mold feeding and more flexible trimming options.

Main Applications

All-in-one Automated Clear Aligner Machine (Film Sheet) – 120 Aligners/Hour is suitable for:

• Clear aligner manufacturers

• Invisible orthodontic appliance factories

• Dental laboratories

• Orthodontic product manufacturers

• Medium-scale aligner manufacturers

• OEM dental appliance factories

• Small-batch aligner production

• Multi-variety aligner production

• Customized orthodontic appliance production

Key Benefits

• Up to 120 aligners/hour production capacity

• Automatic teeth mold feeding

• Visual mold recognition above 98%

• Compatible with multiple film sheet formats

• Adjustable 0–700°C thermoforming temperature

• ABB 6-axis robotic trimming

• 0.02 mm repeated positioning accuracy

• Integrated laser marking

• Optional laser trimming

• Automated production workflow

• Suitable for small-batch and multi-variety manufacturing

Supplier Information

ConverSight Technology Limited provides automated equipment solutions for clear aligner and invisible orthodontic manufacturing. The equipment integrates film feeding, mold loading, thermoforming, laser marking, and precision trimming to support efficient dental appliance production.

For manufacturers seeking All-in-one Automated Clear Aligner Machine (Film Sheet) – 120 Aligners/Hour, this system offers flexible film compatibility, automated mold handling, precision robotic trimming, and integrated production functions for modern clear aligner factories.