All-in-one Automated Clear Aligner Machine – 120 Aligners/Hour

Product Introduction

All-in-one Automated Clear Aligner Machine – 120 Aligners/Hour is an integrated automated production system designed for middle- to large-scale clear aligner manufacturers, orthodontic appliance producers, and OEM factories. The machine combines film feeding, teeth mold loading, thermoforming, laser marking, and precision trimming into one automated workflow.

With a production capacity of up to 120 clear aligners per hour and a working cycle of approximately 30 seconds per piece, the system is designed to reduce manual intervention and improve production consistency. It supports both film rolls and film sheets, providing greater flexibility for different manufacturing processes.

The HBL-YTJ-02 machine integrates automatic film cutting, visual mold recognition, thermoforming, laser marking, and CNC or optional laser trimming, creating a continuous production process from raw film and dental molds to finished clear aligners.

Key Product Features

• 120 Aligners/Hour Capacity: Designed for high-volume clear aligner production with a working efficiency of approximately 30 seconds per piece.

• Full Workflow Automation: Integrates automatic material feeding, thermoforming, marking, and trimming to reduce manual handling.

• Automatic Film Cutting: The updated system includes an automatic film cutting module for continuous production.

• Automatic Teeth Mold Feeding: Supports automatic feeding and positioning of dental molds with visual recognition.

• Flexible Film Input: Compatible with film rolls and both round and square film sheets.

• High-Fitting-Pressure Thermoforming: Evenly heats and softens film to form clear aligner prototypes with consistent fitting performance.

• Adjustable Heating: Thermoforming temperature can be adjusted within a range of 0–700°C according to process requirements.

• Precision Robotic Trimming: An ABB 6-axis robot provides flexible trimming for complex, irregular, and curved aligner geometries.

• Millimeter-Level Control: Robotic trimming supports consistent edge processing with an edge consistency specification below 0.3 mm.

• Laser Marking: Supports numbers, letters, barcodes, QR codes, and logos for product identification and traceability.

• Optional Laser Trimming: Customers can select laser trimming as an alternative to blade/CNC trimming.

• Water-Cooled Spindle: The 800W spindle operates at rotational speeds below 40,000 r/min and uses water cooling for heat dissipation.

Integrated Production Workflow

The All-in-one Automated Clear Aligner Machine – 120 Aligners/Hour is designed around a continuous production workflow.

1. Automatic Film Loading

The machine automatically handles film material and supports film rolls with a diameter of up to 450 mm. Film widths from 100–137 mm are supported.

2. Automatic Teeth Mold Feeding

Dental molds can be automatically supplied through the feeding system. The visual recognition system identifies and positions molds accurately on the machine tooling.

The mold feeding system accommodates 4 × 24 molds, or 96 pieces in total, allowing approximately one hour of unattended operation under the stated production conditions.

3. Thermoforming

The film is evenly heated and softened before being formed over the dental mold. The adjustable 0–700°C heating range allows the thermoforming process to be configured according to material and production requirements.

4. Laser Marking

After forming, the machine can mark identifying information directly onto the aligner or designated area. Supported marking content includes numbers, letters, barcodes, QR codes, and logos.

5. Precision Trimming

The system uses a robotic trimming module for flexible processing of aligner edges and complex geometries. Standard configurations support CNC/blade trimming, while laser trimming is available as an optional function.

Technical Specifications

Robotic Trimming System

The trimming system incorporates an ABB 6-axis robot for high-precision processing. Its flexible multi-axis movement enables trimming along complex, irregular, and curved aligner contours.

Robot Specifications

• Robot type: ABB 6-axis

• Arm span: 703 mm

• Robot weight: 54 kg

• Payload: 7 kg

• Power: 0.39 kW

• Repeated positioning accuracy: 0.02 mm

The robotic system is designed to improve trimming consistency and reduce variation caused by manual operations.

Spindle Module

The spindle module provides high-speed cutting performance for automated trimming applications.

• Power: 800 W

• Rotational speed: <40,000 r/min

• Heat dissipation: Water cooling

The high-speed spindle works together with the robotic positioning system to process aligner edges according to programmed trimming paths.

Automatic Teeth Mold Recognition

The automatic feeding system uses visual recognition to identify and position dental molds. The stated recognition rate is above 98%, helping improve feeding accuracy and reduce manual positioning operations.

The system can accommodate up to 96 dental molds through four boxes, providing a continuous supply for approximately one hour of unattended operation under the specified production conditions.

Production Quality Control

The machine is designed to improve process consistency through automated material handling, visual recognition, robotic trimming, and integrated process control.

Specified production indicators include:

• Visual recognition rate: >98%

• Edge consistency: <0.3 mm

• Raw edge rate: <2%

• Cut defect rate: <1%

• Repeated robot positioning accuracy: 0.02 mm

These parameters support consistent processing for high-volume clear aligner manufacturing.

Film Compatibility

The updated machine supports multiple film input formats, giving manufacturers more flexibility when selecting production materials.

Supported options include:

• Film rolls

• Round film sheets

• Square film sheets

• Film width: 100–137 mm

• Film roll diameter: up to 450 mm

This flexible material handling design allows the system to be integrated into different clear aligner production workflows.

Machine Generation Upgrade

The HBL-YTJ-02 represents an upgraded generation compared with the previous system.

The updated design increases production capacity from 90 to 120 pieces per hour while adding automatic mold feeding and more flexible film input options.

Main Applications

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

• Clear aligner manufacturers

• Orthodontic appliance manufacturers

• Dental laboratory production

• Middle-scale aligner factories

• Large-scale aligner factories

• OEM clear aligner factories

• Customized orthodontic product manufacturers

• High-volume dental appliance production

The machine is particularly suitable for manufacturers looking to increase automation and reduce manual operations across the clear aligner production process.

Benefits for Clear Aligner Manufacturers

Higher Production Throughput

With a rated capacity of up to 120 aligners per hour, the machine is designed for higher-volume manufacturing requirements.

Reduced Manual Intervention

Automatic film feeding, mold recognition, thermoforming, marking, and trimming reduce the number of manual production steps.

Improved Process Consistency

Automated positioning and robotic trimming help maintain consistent processing quality across production batches.

Flexible Production Materials

Support for film rolls and film sheets allows manufacturers to select materials according to their existing production systems.

Integrated Equipment Design

Combining several production processes in one machine can simplify equipment integration and reduce the need for separate processing stations.

Supplier Information

ConverSight Technology Limited develops automated equipment for clear aligner manufacturing and orthodontic production applications. The HBL-YTJ-02 integrates material handling, thermoforming, laser marking, and precision trimming into a single automated production platform.

For manufacturers planning to upgrade their clear aligner production line, All-in-one Automated Clear Aligner Machine – 120 Aligners/Hour provides a high-capacity solution with automatic feeding, flexible film handling, robotic trimming, and optional laser processing.

For technical evaluation or quotation, buyers can provide their required production capacity, film format, aligner specifications, automation requirements, and factory layout so the appropriate machine configuration can be assessed.