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Excellence in Every Step

Customization Process

In order to manufacture an outstanding appliance it is necessary to combine advanced ordering, design, and manufacturing technologies to create the 100% customized and highly precise Incognito™ Appliance System. The following guide outlines this unique and highly-technical process.

1Impressions and Ordering

The Incognito System fabrication process begins with an impression. Submit the impression, wax bite, and patients prescription via a Lab Order Form.

The laboratory uses the impression to create maloccluded models. They are the basis for the preparation of the physical and digital setup.

Impressions and Ordering

Complete the laboratory order specifying the details of the patient and the orthodontist, the address, scheduled bonding date and a legibly completed treatment plan.

Take an impression of your first patient.

Impressions and Ordering

Put together the Lab Order Form, the impressions and the wax bite and send them to TOP-Service für Lingualtechnik GmbH (Laboratory).

Impressions and Ordering

2Incognito Lab and Customer Care Teams

The lab team creates a model of the malocclusion from the impression. This model is the basis for the preparation of the setup.

Since a bad impression/model could mean that the brackets do not fit the patient upon delivery, the model is checked for quality before moving through the rest of the process. Our specially trained Customer Care team confirms that 3M Unitek can deliver a quality product and provides support during the entire process, acting as the main contact for all treatment-related questions.

Incognito Lab and Customer Care Teams

3Setup Process

Regardless of the option - Manual or Digital Setup - highly qualified 3M Unitek technicians produce the setup according to the doctor's individual prescription and Andrews' Six Keys.

Manual Setup

Digital Setup

Setup Process Setup Process

4Computer-Aided Bracket Design

The digital design of the bracket relies exclusively on the setup scan. Customized bracket pads and bases are designed using the lingual surface of the digital model.

The height, width, torque and angulations of each bracket body are customized and assembled on the base in the optimal position, based on the unique prescription for each patient. Each wing is adjusted with the intent of optimizing comfort and tie-wing functionality, while each pad size is customized and designed to deliver optimal bond strength.

Computer-Aided Bracket Design Computer-Aided Bracket Design
Computer-Aided Bracket Design Computer-Aided Bracket Design
Computer-Aided Bracket Design

5Prototyping

A rapid prototype process is used to print patterns of the digitally designed customized brackets. During the prototyping process, the customized brackets are made in an additive manner layer by layer. This method ensures that the subsequent casting process will be perfect.

Prototyping

6Casting

Bracket models created in wax are embedded in molds and then cast in gold.

Casting Casting
Casting Casting

7Tumbling and Refinement

Once the gold brackets are separated from the casting channel, they are polished.

Barelling

Tumbling and Refinement

Polishing

Tumbling and Refinement

Cast » Barelled » Polished

Tumbling and Refinement

8Quality Assurance

Finally, the slot dimension is manually checked in every bracket and, if it doesn't meet the standard, a new bracket will be manufactured.

Quality Assurance

9Archwire Bending

Customized archwire geometry is determined by the prescription and the CAD/CAM software.

Each steel and Beta Titanium wire in the sequence is designed based on the target occlusion and bent to the final result using robotic technology. The super elastic Unitek™ Nitinol wires are manually programmed and bent using heat and specialized plates.

Archwire Bending Archwire Bending

10Bonding Tray and Customization

As the last step, the trays are made on the malocclusion model, to make sure that the brackets are precisely and efficiently transferred to the patients mouth.

Therefore a 100% customized bonding tray is made based on the maloccluded model to transfer the brackets precisely and efficiently to the patient's mouth.

Bonding Tray and Customization Bonding Tray and Customization

Sillicon tray

Clear tray

Bonding Tray and Customization Bonding Tray and Customization

11Final Check and Shipping

In the final step, all materials are checked against the order before shipping.

The final result, a 100% customized appliance system that includes brackets, archwires and bonding trays, is shipped to the orthodontist for treatment.

Final Check and Shipping
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