Abstract
BACKGROUND: The mechanical properties of directly 3D-printed clear dental aligners are currently constrained by the limitations of available 3D printing materials. This study aimed to investigate the mechanical properties of direct 3D-printed clear resin embedded with orthodontic wire under different surface treatments to propose a novel integration method for orthodontic appliances and treatment. METHODS: The stainless-steel wires were divided into three groups based on surface treatments: control groups (C), sandblasting group (S), sandblasting and acid etching group (SA). Surface characteristics were analyzed and interfacial shear strength (IFSS) was measured. Dumbbell-shaped specimens were fabricated using 3D-printed clear resin and divided into four groups, depending on whether they were embedded with stainless-steel wires subjected to different surface treatments. The static and dynamic mechanical properties tests were carried out to calculate elastic modulus, tensile strength, and stress relaxation. RESULTS: The average roughness and surface morphology of stainless-steel wires exhibited significant differences (P < 0.001) following different surface treatments. Sandblasting and acid-etching significantly enhanced IFSS, resulting in a fivefold increase to 28.8 MPa. The elastic modulus and tensile strength of the 3D-printed resin embedded with wires were significantly higher than those of the pure 3D-printed resin group. However, no significant differences in elastic modulus were observed among the different wire surface treatment groups. The sandblasting and acid-etching group exhibited higher residual stress compared to the other groups during both 6-hour and cyclic stress relaxation tests. CONCLUSION: This study presents a novel approach to 3D-printed clear dental aligners integrated with metal wires for orthodontic treatment. Surface treatment of orthodontic metal wire through sandblasting and acid etching enhances the bonding strength between the wire and 3D-printed clear resin, improving the static and dynamic mechanical properties of directly 3D-printed clear resin appliances. The innovative process and device provide an integrated solution for digital orthodontic treatments.