In recent years, additive manufacturing (AM) has been recognized as a transformative force in the dental industry, with the ability to address escalating demand, expedite production timelines, and reduce labor-intensive processes. Despite the proliferation of three-dimensional printing technologies in dentistry, the absence of well-established post-processing protocols has posed formidable challenges. This comprehensive review paper underscores the critical importance of precision in post-processing techniques for ensuring the acquisition of vital properties, encompassing mechanical strength, biocompatibility, dimensional accuracy, durability, stability, and aesthetic refinement in 3D-printed dental devices. Given that digital light processing (DLP) is the predominant 3D printing technology in dentistry, the main post-processing techniques and effects discussed in this review primarily apply to DLP printing. The four sequential stages of post-processing support removal, washing, secondary polymerization, and surface treatments are systematically navigated, with each phase requiring meticulous evaluation and parameter determination to attain optimal outcomes. From the careful selection of support removal tools to the consideration of solvent choice, washing methodology, and post-curing parameters, this review provides a comprehensive guide for practitioners and researchers. Additionally, the customization of post-processing approaches to suit the distinct characteristics of different resin materials is highlighted. A comprehensive understanding of post-processing techniques is offered, setting the stage for informed decision-making and guiding future research endeavors in the realm of dental additive manufacturing.

Clear aligners have revolutionized orthodontic treatment by offering an esthetically driven treatment modality to patients of all ages. Over the past two decades, aligners have been used to treat malocclusions in millions of patients worldwide. The inception of aligner therapy goes back to the 1940s, yet the protocols to fabricate aligners have been continuously evolved. CAD/CAM driven protocol was the latest approach which drastically changed the scalability of aligner fabrication—i.e., aligner mass production manufacturing. 3D printing technology has been adopted in various sectors including dentistry mostly because of the ability to create complex geometric structures at high accuracy while reducing labor and material costs—for the most part. The integration of 3D printing in dentistry has been across, starting in orthodontics and oral surgery and expanding in periodontics, prosthodontics, and oral implantology. Continuous progress in material development has led to improved mechanical properties, biocompatibility, and overall quality of aligners. Consequently, aligners have become less invasive, more cost-effective, and deliver outcomes comparable to existing treatment options. The promise of 3D printed aligners lies in their ability to treat malocclusions effectively while providing esthetic benefits to patients by remaining virtually invisible throughout the treatment process. Herein, this review aims to provide a comprehensive summary of studies regarding direct-3D printing of clear aligners up to the present, outlining all essential properties required in 3D-printed clear aligners and the challenges that need to be addressed. Additionally, the review proposes implementation methods to further enhance the effectiveness of the treatment outcome.