Smile Direct Club

Lack of precise force measurement in dental aligners leads to inefficient treatments, discomfort, and unpredictable results.

Dental aligners have become a popular alternative to traditional braces, offering a cost-effective, less invasive, and efficient way to straighten teeth. Smile Direct Club has innovated in this space by providing custom aligner sets tailored to each customer’s journey, gradually adjusting their teeth from the current state to the desired position. However, determining the right amount of movement for each aligner step is a complex challenge. Pushing too hard can cause pain, while not pushing hard enough can extend treatment times or render it ineffective.

To address these issues, Smile Direct needed precise data about how each aligner interacts with teeth. Tooth movement is not isolated; pushing one tooth affects its neighbors, leading to a cascading effect that’s difficult to predict. The company also faced challenges in quantifying customer complaints about pain and determining whether complaints stemmed from excessive force or individual sensitivity.

Threading the Needle of Patient Needs and Business Outcomes

Navigating Trade-Offs of Comfort and Efficiency

Through in-depth exploration, we realized Smile Direct’s challenges extended beyond pain management. They were creating treatment plans without fully understanding the dynamic interplay between teeth—moving one tooth impacts others in cascading ways that are difficult to predict. Addressing these complexities meant not only improving aligner efficiency but also ensuring the patient experience remained comfortable. Excessive pain could lead to customer dissatisfaction, cancellations, and revenue loss. By deeply analyzing these challenges, Ovyl helped Smile Direct craft a system that balanced precision, patient comfort, and business outcomes—leading to better treatment plans, improved customer retention, and a stronger market position.

Exploring Materials and Approaches

Building upon Smile Direct’s initial 3-tooth setup, Ovyl reviewed extensive research materials, patents, and reports. Through detailed discussions, the team identified key technical hurdles, including how to scale the system from 3 to 16 teeth. The team:

• Researched and tested motor controllers capable of delivering precision down to 0.00005 mm increments.
• Experimented with designs to achieve multi-axis movement, confirming that certain approaches weren’t feasible.
• Selected and iterated on components that met the demanding requirements for precision and reliability.

Mechanical Design and Development

Ovyl designed and developed the mechanical system with a focus on delivering precision and reliability, which is crucial for meaningful data collection. To ensure stability and eliminate unintended movement, all mounted components were crafted from durable steel or aluminum. High-resolution linear actuators provided the exacting control required to limit variability and achieve accurate research outcomes. Recognizing the sensitivity of temperature fluctuations and air movement on test results, Ovyl also designed an acrylic cover to maintain a controlled environment while preserving visibility for users. This robust, carefully engineered system allowed Smile Direct to test a variety of aligner configurations effectively, translating sensor readings into actionable insights for treatment planning.

Custom Software

The software solution balanced automation and control. Ovyl developed algorithms that allowed for fully automated scripted control while also offering an expert user mode for precise adjustments. Thanks to built-in safeguards like force gauge monitoring, this dual-mode system empowered users to control forces on individual teeth without risking device damage.

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A Data-Driven Breakthrough in Dental Alignment

The result was a groundbreaking device featuring:

• An array of 3D-printed teeth capable of microscopic positional adjustments along two axes (down to 0.00005 mm increments).
• Sensors that measure force changes in six degrees of freedom, capable of reading forces in the 2-6 gram range.
• The ability to sample data from 16 teeth simultaneously and control 32 linear actuators with exceptional precision.

This system enabled Smile Direct to collect detailed data on tooth-aligner interactions, optimizing aligner designs and treatment plans. The device not only addressed the problem of quantifying and minimizing pain but also enhanced the overall efficiency and effectiveness of treatment.

By leveraging this advanced system, Smile Direct could provide faster, more comfortable treatment experiences for patients, ultimately leading to more confident smiles and solidifying their leadership in the dental aligner market.

Recognition

Ovyl was honored to receive a Notable Commercial Equipment Award in the 2023 Core77 Design Awards.

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