Auto-Thermoforming Machine

How to save money with an auto thermoforming machine

If your orthodontic practice produces a high volume of aligners/retainers, you may want to consider investing in an auto thermal forming machine. This machine automates the process of forming aligners, significantly reducing costs and improving efficiency.

What is an Auto Thermal Forming Machine?

This machine automates the process of forming plastic around a 3D printed model to form aligners and retainers. The machine featured in this post has an automatic model feeder that can be stacked to any height, making it adaptable to different workspace constraints. The prototype version of this machine (as seen in the video) processes up to 100 aligners or models per hour. However, their latest model can thermoform approximately 500 models per hour and offers an optional laser inscribing feature for added customization. There is a climate controlled storage area at the base of the machine that maintains the integrity of the plastic roll while the aligners are being processed.

Why Should a High-Volume Practice Invest in One?

Initially, I was skeptical about whether this machine would be cost-effective. We already have multiple Biostar machines that can produce aligners quickly, and the labor cost for manual production seemed reasonable. However, the real savings come from the cost of plastic.

We use Zendura Flex plastic, which typically costs about $4 per sheet, even with a discount. In our practice alone, we produce approximately 1,200 aligners/retainers per month. With traditional methods, that adds up to a substantial expense. However, when using the roll-fed system of the auto thermal forming machine, the cost per model drops to around $1. This translates to a savings of about $3 per aligner—equating to an annual savings of $40,000 to $45,000.

Investment and ROI

Their newer machine costs around $70,000, although cheeper options may be available. Given the cost savings on plastic alone, most practices can recoup that investment within two years. Additionally, there are labor savings to consider, making it an even more worthwhile investment for high-volume practices.

Is This Machine Right for Your Practice?

If your practice produces a high volume of aligners and retainers, this machine could be a game-changer. Not only does it save money, but it also streamlines production and enhances efficiency.

If you're interested in learning more, feel free to reach out to me. I can connect you with the manufacturers—just let them know I sent you 😉. It’s been an excellent addition to our workflow, and I believe it could provide similar benefits to other high-volume orthodontic practices.

Let me know if you have any questions, and I’d be happy to share more about my experience.

— Aaron