LightForce 3D Prints Custom Metal Braces Near Boston

How LightForce Makes Braces That Actually Fit

LightForce Orthodontics runs a 3D printing facility in Wilmington, Massachusetts, and it is changing how orthodontic treatment works. Instead of using the same off-the-shelf metal brackets for every patient, the company creates brackets that are unique to each tooth. Every bracket gets its own identification number and is 3D printed in metal to match that patient's digital scan.

The result is a set of braces that fits the exact shape of a patient's teeth. Alfred Griffin, co-founder of LightForce, put it plainly: Teeth are as unique as fingerprints. Braces should be as unique as the patient.

Katie Doran, LightForce's Vice President of Operations, was the first person to wear the company's custom metal braces. She completed treatment in about seven and a half months with just six appointments. Traditional braces usually take longer and require more adjustments. LightForce says its system cuts treatment time by roughly half and reduces office visits by up to 60%.

The company has produced around 16 million unique brackets for approximately 200,000 patients so far. The process starts with a digital scan from the orthodontist's office. LightForce then prints and ships the custom brackets back in about a month.

Griffin says the biggest challenge was scaling 3D-printed braces to meet demand. Metal 3D printing has been used in automotive and aerospace for years, but dental work requires far tighter tolerances. In the mouth, millimeters matter, he said. Every fraction of a millimeter has a big impact on that patient's bite and their esthetic outcome.

LightForce is now offering its LightBracket Metal system to orthodontists across the country. The move to patient-specific metal brackets represents a shift away from the one-size-fits-all approach that dominated orthodontics for decades. For patients, that means fewer appointments, shorter treatment, and braces that are built for their actual teeth.