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A novel methodology for assessing, evaluating, and classifying defects in clear aligner attachments

Open Access
|Jun 2025

Figures & Tables

Figure 1.

There are mild discrepancies (yellow = 0.1–0.3mm) in tooth shape when T0 is aligned with T1. As these teeth are aligned individually, this discrepancy can be attributed to scanning errors or changes in the tooth’s shape. Due to the location and clinical feedback, this change in shape was attributed to the scanner detecting different volumes of dental plaque between T0 and T1.
There are mild discrepancies (yellow = 0.1–0.3mm) in tooth shape when T0 is aligned with T1. As these teeth are aligned individually, this discrepancy can be attributed to scanning errors or changes in the tooth’s shape. Due to the location and clinical feedback, this change in shape was attributed to the scanner detecting different volumes of dental plaque between T0 and T1.

Figure 2.

A, Occlusal image of maxillary arch aligned to best fit showing discrepancies on unaffected surfaces attributed to small dental movements. B, A linear section through the upper right central incisor, with the upper right central incisor individually aligned to best fit. There is reasonable alignment across the whole crown, with significant discrepancies related only to the attachment. C, The same section through the upper right central incisor as in Figure 2B; however, this section shows the discrepancies across the crown and attachment surfaces. D, The occlusal image of the maxillary arch aligned to a single tooth (upper right canine) shows an ideal fit for this tooth but significant discrepancies on all other teeth.
A, Occlusal image of maxillary arch aligned to best fit showing discrepancies on unaffected surfaces attributed to small dental movements. B, A linear section through the upper right central incisor, with the upper right central incisor individually aligned to best fit. There is reasonable alignment across the whole crown, with significant discrepancies related only to the attachment. C, The same section through the upper right central incisor as in Figure 2B; however, this section shows the discrepancies across the crown and attachment surfaces. D, The occlusal image of the maxillary arch aligned to a single tooth (upper right canine) shows an ideal fit for this tooth but significant discrepancies on all other teeth.

Figure 3.

A, Attachment overfill error. (i) shows the ideal attachment, and (ii) shows the placed attachment. (iii) superimposes these two to demonstrate the degree of error. B, Resin underfill demonstrated with three 2D slices, with the ideal attachment outline in black and the actual attachment deficit highlighted with coloured lines. C, Two images demonstrating the ideal attachment (i) and the actual attachment (ii). Bowing in the middle third is observed due to occlusal pressure distorting the attachment template during curing. D, Three images showing no definable attachment ridges when only the accurate points are displayed (i)resulting in an attachment shape (ii) being unrecognisable from the planned attachment (iii). E, While the faces and ridges of the attachment appear to be intact, there is a partial separation of the attachment from the tooth surface at the base. This is attributed to underfilling the attachment template in one section so that although the attachment bonds to the tooth, the base is not circumferentially intact. F, Abrasion is shown on a 36 (iv). The accuracy of the initial attachment is shown (i) compared to the attachment after 11 months of treatment (ii-v). The abrasion appears to be due to occlusal load on a specific portion of the 36 attachment (vi). Similar changes are observed on the 35, and flash is visible on the mesial aspect of the 36. G, A series of images shows an ideally shaped and volumetrically accurate attachment (ii-iii) placed more incisal than the planned attachment (i). H, An image showing a surface bubble (i) and comparison with the ideal (ii); this image also demonstrates overfill and flash. I, A model (i) and image (ii) with an arrow identifying a porosity inside an attachment. J, Surface roughness of a new attachment (i) and old attachment (ii) attributed to the surface roughness of the template being replicated in the attachment. K, Flash is demonstrated in yellow surrounding the underfilled (blue) attachment and aligned (green) tooth. L, A debonded or missing attachment is noted as a blue rectangle on the otherwise aligned (green) tooth. This tooth also has a yellow area; this difference between T0 and T1 is attributed to dental plaque.
A, Attachment overfill error. (i) shows the ideal attachment, and (ii) shows the placed attachment. (iii) superimposes these two to demonstrate the degree of error. B, Resin underfill demonstrated with three 2D slices, with the ideal attachment outline in black and the actual attachment deficit highlighted with coloured lines. C, Two images demonstrating the ideal attachment (i) and the actual attachment (ii). Bowing in the middle third is observed due to occlusal pressure distorting the attachment template during curing. D, Three images showing no definable attachment ridges when only the accurate points are displayed (i)resulting in an attachment shape (ii) being unrecognisable from the planned attachment (iii). E, While the faces and ridges of the attachment appear to be intact, there is a partial separation of the attachment from the tooth surface at the base. This is attributed to underfilling the attachment template in one section so that although the attachment bonds to the tooth, the base is not circumferentially intact. F, Abrasion is shown on a 36 (iv). The accuracy of the initial attachment is shown (i) compared to the attachment after 11 months of treatment (ii-v). The abrasion appears to be due to occlusal load on a specific portion of the 36 attachment (vi). Similar changes are observed on the 35, and flash is visible on the mesial aspect of the 36. G, A series of images shows an ideally shaped and volumetrically accurate attachment (ii-iii) placed more incisal than the planned attachment (i). H, An image showing a surface bubble (i) and comparison with the ideal (ii); this image also demonstrates overfill and flash. I, A model (i) and image (ii) with an arrow identifying a porosity inside an attachment. J, Surface roughness of a new attachment (i) and old attachment (ii) attributed to the surface roughness of the template being replicated in the attachment. K, Flash is demonstrated in yellow surrounding the underfilled (blue) attachment and aligned (green) tooth. L, A debonded or missing attachment is noted as a blue rectangle on the otherwise aligned (green) tooth. This tooth also has a yellow area; this difference between T0 and T1 is attributed to dental plaque.

Figure 4.

Fundamental attachment morphologies.
Fundamental attachment morphologies.

Figure 5.

Hemi-Ellipsoid attachment trimmed from an ellipsoid attachmen.
Hemi-Ellipsoid attachment trimmed from an ellipsoid attachmen.

Figure 6.

A, The attachment Active Surface(s) (Green) is where force is applied. B, The attachment Passive Surface(s) (Grey). C, The attachment Ridges (Orange) divide the faces of the attachment and define the shape. D, The attachment Base (Red) bonds the attachment to the tooth.
A, The attachment Active Surface(s) (Green) is where force is applied. B, The attachment Passive Surface(s) (Grey). C, The attachment Ridges (Orange) divide the faces of the attachment and define the shape. D, The attachment Base (Red) bonds the attachment to the tooth.

Common attachment defects classification

Defects that fundamentally change the attachment size.
OverfillExcess composite resin associated directly with the attachments’ surfaces results in an attachment that is larger volumetrically than planned. The overall shape of the attachment can be accurate; however, excess resin in the template causes the attachment to protrude further than intended (Figure 3A)
UnderfillA deficiency in the composite resin results in decreased attachment volume and smaller surfaces than planned. However, the overall shape of the attachment remains intact (Figure 3B)
VolumetricBowingA discrepancy that results in one or more attachment surfaces being distorted towards the centre of the attachment ridges, creating a bowed appearance. This is most likely attributed to distortion within the attachment template because of pressure on this more flexible part of the template (Figure 3C)
ShapeAttachments with a significant volumetric error so that the ridges are not accurately reproduced, resulting in a defect in the overall shape (Figure 3D)
SeparationThe shape of the attachment ridges and the active and passive faces are intact; however, there is a substantial volumetric defect at the base of the attachment between the attachment and the tooth (Figure 3E)
AbrasionAbrasion is the gradual loss or distortion of an attachment due to mechanical and/or chemical interactions. Attachments exist in the oral environment; abrasion of attachments occurs through normal oral functions and repeated removal and replacement of aligners. (Figure 3F)
LocationalDefects due to the attachment being bonded in a position other than what was planned (Figure 3G)
ErrorsDefects in attachments that do not fit into one of the other categories
BubblesThere is a minor round volumetric error at the surface of the attachments (Figure 3H)
PorositiesBubbles in the composite resin that are contained within the body of the attachment. These may not affect the overall dimensions of the attachment; however, they may affect its structural integrity and the aesthetics of the attachment (Figure 3I)
RoughnessIncreased surface roughness when compared to the ideal CAD-CAM design due to the attachment template being formed on a coarse 3D printed model (Figure 3J)
FlashA thin layer of excess composite around the perimeter of the attachment, which does not affect the attachment volume but may compromise the accuracy of the location of the attachment (Figure 3K)
BondingFailure of the bonding of the attachment to the tooth (Figure 3L)
DOI: https://doi.org/10.2478/aoj-2025-0014 | Journal eISSN: 2207-7480 | Journal ISSN: 2207-7472
Language: English
Page range: 177 - 187
Submitted on: Jan 1, 2025
Accepted on: Apr 1, 2025
Published on: Jun 3, 2025
Published by: Australian Society of Orthodontists Inc.
In partnership with: Paradigm Publishing Services
Publication frequency: 1 times per year

© 2025 Linton J. Nash, Haylea L. Blundell, Tony Weir, published by Australian Society of Orthodontists Inc.
This work is licensed under the Creative Commons Attribution 4.0 License.