AAO 2025 Philadelphia [SHOW PREVIEW]: PRedicting the MOST Innovative Technologies in Orthodontics

The American Association of Orthodontists (AAO) Annual Session is the must-attend event for orthodontic professionals, showcasing the latest innovations and technologies set to transform the industry. The AAO 2025 is set to take place at the Philadelphia Convention Center, hosted Friday April 25-Sunday April 27, 2025.

The 2025 session promises to deliver game-changing advancements that will redefine treatment planning, improve workflows, and elevate patient outcomes. From direct-print aligners to artificial intelligence and enhanced digital workflows, here are the top technologies poised to make a big splash at the AAO 2025 in Philadelphia.

3D Printing: Direct-Print Aligners - The Rise of In-Office Production

While there is certainly bound to be a lot of buzz around 3D Printing at the AAO this year, one technology is preparing to disrupt traditional methods of thermoforming on 3D printed models. For years, orthodontists have been waiting for a 3D printing system advanced enough to produce same-day aligners and other ortho appliances. Today, we can definitively say this technology has arrived thanks to LuxCreo!

• LuxCreo iLux Pro Ecosystem: LuxCreo is currently leading the market with its direct-print aligner system, capable of 3D printed aligners, nightguards and other ortho appliances. With this big disruption to traditional thermoforming methods, orthodontists can now produce same-day aligners tailored to each patient's needs, streamlining mid-treatment adjustments and saving significant time as well as material costs. For more on this topic, check out our webinar recap:
• Why It Matters: Direct-print aligners allow orthodontists to provide faster, customized treatments while maintaining full control over production, resulting in reduced material costs and improved patient satisfaction.

AI-Powered Treatment Planning and Simulation

Artificial intelligence (AI) is taking orthodontic workflows to the next level by enabling fast, precise treatment planning and virtual simulations. AI-powered tools reduce the manual effort required for diagnosis, enhance accuracy, and improve treatment predictability.

• AI Diagnostics: AI can analyze 3D scans to predict tooth movement, identify potential challenges, and simulate treatment outcomes, providing clinicians with valuable insights.
• Why It Matters: AI eliminates time-consuming tasks, ensures consistent results, and improves treatment efficiency, allowing orthodontists to focus more on patient care.

Digital WorkflowS for Orthodontics

The adoption of fully integrated digital workflows is transforming orthodontic practices by streamlining processes, reducing errors, and enhancing collaboration. At the AAO 2025, expect a spotlight on technologies that bring together digital scanning, CAD software, 3D printing, and cloud-based management systems into a cohesive workflow.

• Seamless Integration: Digital workflows connect all aspects of orthodontic treatment—from intraoral scanning to treatment planning, appliance fabrication, and patient monitoring—into a single, efficient system.
• Cloud-Based Solutions: Platforms like 3Shape Communicate and OrthoCAD enable orthodontists to collaborate with labs and share files in real time, ensuring faster turnaround and improved communication.
• Intraoral Scanning: Advanced scanners like the iTero® Lumen & 3Shape TRIOS 5 provide highly detailed, precise scans that can be seamlessly integrated into CAD software for aligner design, wire bending, and appliance fabrication.
• Why It Matters: By eliminating paper-based processes and manual steps, digital workflows improve efficiency, ensure consistency, and allow for faster treatment delivery. Orthodontic practices benefit from increased productivity and reduced operational errors.

Robotic Wire Bending Technology

Robotic wire bending is a game-changer for creating precise, customized archwires quickly and efficiently. By automating what was once a manual, labor-intensive process, robotic systems are improving both accuracy and workflow efficiency.

• Yoat Bender 2: This advanced robotic wire bending system integrates seamlessly with CAD software, automatically producing patient-specific archwires with micron-level precision. It handles complex bends, including torque, angulation, and finishing adjustments.
• Why It Matters: Robotic wire bending reduces chairside adjustments, minimizes human error, and saves time, allowing orthodontists to focus on clinical care while improving treatment predictability.

Smart Bracket Systems with Real-Time Monitoring

The next frontier in orthodontics involves smart bracket systems equipped with sensors to track tooth movement, force application, and patient compliance in real time. These brackets send data back to the clinician, allowing for more proactive treatment adjustments.

• Sensor Technology: Smart brackets can monitor force levels and detect if a bracket is underperforming, ensuring precise and efficient treatment.
• Why It Matters: Real-time monitoring improves treatment accuracy, reduces mid-course corrections, and ensures patients remain on track for faster results.

Cloud-Based Digital Management Systems

Digital management platforms are helping orthodontic practices modernize their workflows, allowing for seamless communication, treatment planning, and case management. Cloud-based systems ensure files, scans, and designs are accessible from anywhere, improving efficiency and collaboration.

• Integrated Platforms: Cloud tools integrate digital impressions, treatment designs, and 3D printing workflows, simplifying case management for multi-location practices and labs.
• Why It Matters: Cloud-based management eliminates delays, reduces errors, and provides orthodontists with the tools to offer high-quality, efficient care.

Looking for the latest in Ortho Tech?

While you're here learning about all the great things you'll find at next year's AAO Annual Meeting, we should go ahead and introduce ourselves!

We’re Voxel Dental, your preferred partner in digital workflow technologies. We'll be at the AAO at Booth #2339 in the Tech Select area.

We’ve helped thousands of dental and specialty practices find 3D printers, intraoral scanners, CAD/CAM softwares, wire bending robots and much more. While you're at the show, stop by and see our show special offers!