10/05/2026
Palone and colleagues from the University of Ferrara describe a workflow for designing and 3D printing orthodontic brackets in-house, then apply them in a two-phase case. After testing several resins, they settled on a biocompatible temporary crown material that balanced rigidity with fracture resistance, with bracket thickness tailored by tooth and .022 slots throughout.
The case is an 8-year-old male with a skeletal Class II, maxillary transverse deficiency, and mesiodens, treated through Phase I expansion with headgear and a Phase II finish using the printed brackets. Treatment progressed conventionally through to .018 by .025 stainless steel, with a few lower premolar brackets fracturing under load and replaced with metal. The case finished in 18 months with coordinated Class I.
The strongest argument for printed brackets is dimensional accuracy and customization. The article is worth reading in full for the workflow specifics, the material comparison data, and the discussion of where in-house printing currently stands against conventional appliances. https://www.jco-online.com/archive/2026/04/269-in-house-3d-printed-brackets-design-fabrication-and-clinical-application/ (subscriber-only)
