Automatic Algorithm to Design Bespoke Teeth Whitening Trays

The growing attention of people to aesthetics has led to a greater demand for dental whitening treatments. Several solutions can be utilized to obtain the desired visual whiteness of teeth but, according to literature, at-home supervised treatments are the standard in dental bleaching. They require soft plastic trays to contain a whitening gel, with active chemical agents, and keep it in contact with the patient’s teeth. The fitting, comfort, and tightness of trays play a fundamental role in the treatment. Any gel leakage can compromise the effectiveness of the treatment and damage soft tissues. Commonly, the trays are ready-made or based on physical dental impressions and manually modified by the dental technician. These procedures have low repeatability and do not always ensure high accuracy. This work presents an automatic digital algorithm to design customized whitening trays. Starting from a digital scan acquisition of the patient’s dental arches, it generates the 3D models of the bespoke trays, in approximately two minutes per arch, ready to be produced by additive manufacturing and thermoforming technologies. The evaluation of the method involved 20 patients. The results emphasize that the custom trays were comfortable and ensured high levels of tightness and fitting.