Orthodontic innovation in 2025 centered on AI integration, digital efficiency, and materials that advanced precision, connectivity, and clinical control.
By Orthodontic Products Staff
Across 2025, orthodontic innovation centered on digital efficiency, AI integration, and material science. From direct 3D printing and cloud-based treatment planning to new aligner materials and AI-powered diagnostics, manufacturers continued to streamline clinical and operational workflows. Here is a look at the year’s most notable product developments and partnerships shaping orthodontic practice.
Aligners & Appliances
Align Technology introduced the Invisalign System with mandibular advancement featuring occlusal blocks (MAOB) for growing Class II patients. Designed for late mixed or early permanent dentition, the system integrates solid occlusal blocks to facilitate earlier vertical opening and mandibular advancement. It offers a single appliance option for cases that might otherwise require multiple treatment phases.
Ormco expanded its Spark Clear Aligner portfolio with Spark Retainers, made from the company’s TruGEN XR material, and BiteSync, a Class II correction system that integrates directly into the Spark workflow. Later in the year, Spark Junior launched to address younger patients with a two-phase treatment plan that transitions seamlessly to advanced aligner therapy.
OrthoFX introduced AirFlex with PrecisionFinish Aligners, designed to maintain active force during finishing stages, improving control, reducing refinements, and enhancing treatment predictability across its aligner portfolio.
Medit entered the aligner market with Medit Aligners, a digital clear aligner solution integrated within the Medit Orthodontic Suite. The system enables orthodontists to simulate, design, and initiate aligner treatment in a single visit, offering same-day starts and full control of treatment design without outsourcing.
Graphy advanced direct 3D-printed aligner technology with its FDA-cleared, CE-marked shape-memory resin. Designed for in-office or lab use, the resin enables direct aligner fabrication without thermoforming. Graphy also partnered with Medit to integrate its material with Medit’s scanning workflows for improved production efficiency.
LuxCreo introduced 4D Bright Aligner, incorporating its ActiveMemory polymer with aesthetic shade technology to produce brighter, more natural-looking aligners without chemical whitening agents. The company also received a strategic investment from Angelalign, aimed at co-developing next-generation 3D printing materials to accelerate adoption of direct-print aligners.
Carbon debuted Lucentra, a new workflow for producing smoother, clearer thermoformed aligners using its UMA 20 material and specialized L1 printer cassette.
EasyRx added automated tools for bleaching trays and sports mouthguards within its 3D AI Services, allowing labs and practices to quickly generate precise models for printing.
Takeaway: The aligner market in 2025 underscored two parallel trends—continued refinement of thermoformed materials for efficiency and esthetics, and growing validation of direct 3D printing as a viable path to customization and speed.
Intraoral Scanning
Dentsply Sirona expanded the Primescan 2 platform with integrated caries detection capabilities and optimized data compression to reduce bandwidth requirements. The company also introduced the Primescan 2 Cart for improved mobility and workflow efficiency, along with a Multi-Use Steel Sleeve to enhance hygiene and sustainability. Updated SureSmile simulations now process up to 90% faster, according to the company, improving real-time patient engagement during consultations.
3Shape introduced the TRIOS 6 scanner with faster color capture, improved ergonomics, wireless adapter, and enhanced patient engagement tools for real-time treatment visualization.
DEXIS introduced the Imprevo intraoral scanner, featuring a slimmer design, faster frame capture, and an extended depth of field to improve scanning comfort and coverage. The scanner integrates with IS ScanFlow 2.0 software, which adds a new Smile Visualizer tool and deeper compatibility with DTX Studio Clinic for case management and diagnostics.
Medit launched Medit Link Express, an iPad-based scanning app designed for mobility, allowing clinicians to capture and share scans without a desktop computer. The app supports real-time patient communication, automatic updates, and seamless transitions between iPad and desktop workflows.
Takeaway: The intraoral scanning landscape continued to move toward mobility, AI-assisted diagnostics, and chairside visualization tools that improve both treatment planning and patient communication.
Imaging & Diagnostics
DEXIS expanded its imaging lineup with the ORTHOPANTOMOGRAPH OP 3D EX and LX, adding cephalometric capabilities, Automatic Dose Control, and streamlined diagnostics within DTX Studio Clinic.
Planmeca added the Viso G1 to its CBCT lineup, offering a smaller field of view (up to 11×11 cm) while maintaining high image quality through motion-correction and low-dose algorithms. The company also introduced the Planmeca ProX GO, its first handheld intraoral X-ray device, designed for chairside efficiency with integrated safety shielding.
Air Techniques released the VistaPano S 2.0, combining panoramic and cephalometric imaging with dual sensors to eliminate manual switching between image types, and a streamlined interface for simplified use in high-volume practices.
AI integration advanced rapidly. Pearl became the first dental AI company with FDA clearance for both 2D and 3D image analysis with its Second Opinion platform. The company also launched Imagecheck, an AI tool that assesses image quality in real time to reduce retakes. Partnerships with Carestream Dental, Vatech, and Dentsply Sirona expanded access to these AI diagnostics within existing imaging systems.
Takeaway: Diagnostic imaging in 2025 reflected an industry-wide shift toward intelligent automation—balancing lower radiation doses with higher precision and real-time image verification.
Platforms & Cloud
Dentsply Sirona confirmed plans to retire Connect Case Center and transition all users to the DS Core platform by the end of 2025. DS Core consolidates imaging, scanning, and case collaboration within a single cloud interface and now supports third-party software integrations through its open API.
uLab Systems advanced its uDesign Cloud workflow, enabling web-based treatment planning and aligner ordering from any device. The company also launched Reva, a thermoforming material for in-office aligner production, and reported a 98% on-time delivery rate for its uSmile aligner line.
Planet DDS introduced DentalOS with AI, embedding automation across imaging, billing, and patient engagement functions. The enterprise platform embeds artificial intelligence into dental service organization (DSO) operations. The company also launched RCM Zero, an end-to-end revenue cycle management solution designed to address inefficiencies in DSOs.
Weave integrated its communication tools with Ortho2 Edge Cloud, enabling synchronized patient contact data, VoIP functionality, and automated reminders.
Intiveo Direct launched as a self-serve engagement platform for practices seeking a cost-effective entry into automated messaging and digital forms.
Takeaway: Cloud migration across practice management, imaging, and treatment planning accelerated in 2025, with vendors focusing on interoperability and reducing administrative complexity.
Remote Monitoring
DentalMonitoring expanded its AI-powered platform with DentalMonitoring+, introducing dynamic 3D visualization of tooth movement and occlusion. The company also launched AIDA Auto Replies to assist with patient messaging and announced multiple new integrations through its Integration Partnership Program—including Ormco Spark, Angel Aligner, ClearCorrect, and major PMS platforms such as Sensei Cloud, Ortho2, and Dolphin Imaging.
Smartee Denti-Technology adopted DentalMonitoring’s SmartSTL technology to generate remote refinement scans without additional in-office appointments, streamlining aligner adjustments.
Grin introduced its new Care, Growth, and Thrive ecosystem, featuring Grin CoPilot—an AI-powered clinical assistant—along with Grin Hygiene+ oral hygiene tracking, an enhanced patient app for engagement and communication, a redesigned doctor portal for streamlined case management, and integration with Clarity by Solventum for unified patient records.
Takeaway: Remote monitoring evolved from an auxiliary feature to a core component of orthodontic care, reducing refinement delays and expanding hybrid treatment models.
3D Printing & Lab Workflows
Dentsply Sirona’s Primeprint Model C added a faster and safer model material compatible with the company’s DS Core ecosystem, allowing practices to complete printing and post-processing in approximately one hour.
3D Systems showcased its NextDent 300 MultiJet printer, designed for multi-material applications including splints and night guards, while previewing direct aligner printing technology expected in 2026.
DEXIS enhanced collaboration between its IS ScanFlow software and exocad DentalCAD, automating data transfer between practices and labs. The company also launched a new lab locator to connect dental laboratories with local practices.
Takeaway: Printing systems are converging on faster cycle times, validated materials, and open compatibility. As direct aligner printing moves closer to clinical reality, production flexibility will become a competitive differentiator for both labs and practices.
Business Tools & Industry Moves
The American Association of Orthodontists (AAO) added Gaidge to its Endorsed Programs, offering member practices discounted onboarding for the analytics platform. The AAO Ortho Innovator Award went to OrthoBerry, recognized for its AI-driven intake and operations system designed to consolidate insurance verification, call management, and payment processing.
At the AAO Annual Session, DentalMonitoring+ and Synapse Dental’s Dental Pain Eraser Kits were named winners in the New Products Showcase.
The AAO announced a strategic investment in DentoAI, an AI-driven case acceptance and scribe platform designed to automate consultations and improve efficiency as part of its Innovation & Transformation Fund initiative.
Angelalign announced its first U.S. manufacturing facility in Wisconsin, signaling continued investment in North American production capacity.
Young Specialties added OrthoNu’s orthodontic self-care products to its distribution portfolio, while OrVance expanded its Aligner Pontics line with a Light Shade and a new indication for retainers.
Takeaway: Product development in 2025 reflected a balanced focus on efficiency, patient experience, and domestic manufacturing—all aimed at supporting orthodontists’ evolving digital workflows. OP
Photo: Thx4Stock team | Shutterstock.com
