6 . BEHIND THE SMILE Alexis Southall , a production associate at the SmileDirectClub facility .
7 . INSPECTION Every aligner undergoes quality control before being sent to its purchaser .
6 THE POWER OF MASS PERSONALIZATION
Ultimately , the partnership between HP and SmileDirectClub , which began formally in 2019 , is collaborative , Baker says . SmileDirectClub relies on HP technology while also helping inform and influence how the technology evolves . For example , his team helped find a way to get printer fuse bulbs to last eight times longer . That lengthened the time that machines could operate before a bulb failed — a periodic event that forces a print failure and wastes materials .
The collaborative spirit kicked into gear in unexpected ways last
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SmileDirectClub says it is on track to make 6.7 million individual 3D-printed molds by the end of the year .
“ 3D printing also reduces the environmental footprint of the manufacturing process in multiple ways ,” says HP ’ s Pastor . In traditional manufacturing supply chains , products are made in one place and then shipped all over the world . With 3D printing , digital files are sent to facilities to be printed locally , saving energy and lowering shipping costs . Instead of mass-producing parts and products , 3D printing also happens on demand , producing only as much as customers ask for , which reduces waste .
And , the process creates more opportunities for recycling , keeping the material in use instead of in landfills . SmileDirectClub sends the molds to HP , where they get chopped into pellets for reuse , primarily for the automotive industry . Consumers can recycle the clear plastic aligners themselves just like plastic bottles .
Last year SmileDirectClub recycled 108 metric tons , or 238,000 pounds , of 3D-printed parts — the equivalent of about 60 automobiles . In collaboration with HP , the company is advancing a new era of digital manufacturing that ’ s fast , highly personalized , and more sustainable than ever before — shortening supply chains , producing less waste than traditional manufacturing , and maximizing recyclability .
GROUP EFFORT SmileDirectClub team members monitor HP 3D printers producing molds for personalized aligners . Aligner therapy is less than half the cost of braces .
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