Testimonial: How LuxCreo 3D Printing Transformed My Orthodontic Workflow

A Testimonial from Dr. David Carter, Carter Orthodontics & Forever Aligned Club

In the ever-evolving world of orthodontics, few technologies have made as dramatic an impact on clinical practice and lab efficiency as direct-print aligners. For Dr. David Carter, founder of Carter Orthodontics in Augusta, SC and visionary behind the Forever Aligned Club, LuxCreo’s direct-printing system—implemented with the help of Voxel Dental—has become a complete game changer. Here's how.

First, watch the video. No time? Continue reading for the recap!

Problem: How to Scale Custom Retainers & Aligners

As the owner of Forever Aligned Club, Dr. Carter set out to create a scalable, affordable solution for long-term tooth alignment. His business model required the ability to produce single retainers and small batch aligners—sometimes as few as 1 to 5 aligners at a time.

But traditional workflows—thermoforming over printed models—were labor-intensive, dusty, and inefficient. As Dr. Carter explains:

“We had to get away from what I call indirect printing... I’ve been kind of waiting for a high-quality direct printed material and printer to come out—and LuxCreo provided that for us.”

Solution: Direct Printing with LuxCreo

Enter the LuxCreo iLux Pro system, available in the U.S. through Voxel Dental. This next-generation technology allowed Dr. Carter and his team to bypass the entire thermoforming and trimming process. The impact?

✅ Cost-effective production of appliances
✅ Cleaner workflow—no dust or trimming debris
✅ Precision in force control through material thickness adjustments

“We can increase the thickness where we need it and decrease it where we need it—something you can’t do with thermoformed aligners.”

Clinical Advantage: Patented Designs, Made Possible

Dr. Carter has even patented orthodontic appliances that weren’t manufacturable using traditional techniques. Now, thanks to LuxCreo’s direct-printing capabilities, he’s finally able to bring those patented designs to life—including a clear spring retainer that enables minor movements without wires or attachments.

“Most patients want a clear retainer… I patented a design that wasn’t possible until LuxCreo came out.”

ROI & Cost Analysis

For Dr. Carter’s mid-sized dental lab, the return on investment (ROI) has been substantial. By eliminating multiple manual manufacturing steps, the lab has achieved:

💰 Lower per-unit costs—under $10 per appliance
📉 Reduced labor variability—no more depending on technician speed
⚙️ Fewer equipment replacements—less depreciation and maintenance

“You really can drill down and say, ‘This is how much each appliance costs me, period.’”

Staff Satisfaction & Workflow Impact

Perhaps the most immediate benefit was felt by Dr. Carter’s team. The elimination of dusty trimming and model production created a safer, cleaner, and more enjoyable work environment.

“My staff absolutely loves it... They’re like, ‘Dr. David, this is so much better. Thank you.’”

He credits the LuxCreo team and Voxel Dental's onboarding experience with making the transition smooth:

“You guys have been great with the training from Voxel... It’s a paradigm shift, and the training had to be exceptional.”

Special shoutout from his team goes to our very own Grant Gallagher, support and training lead here at Voxel Dental, praised for his exceptional support throughout implementation.

Final Verdict

Dr. Carter’s testimonial paints a clear picture: LuxCreo’s direct-print aligner system is not just an upgrade—it’s a revolution. Whether you’re running a single orthodontic practice or managing a growing lab, this technology delivers clinical freedom, operational efficiency, and patient-centered results.

“If you’re using any other kind of printer right now, you need to take a hard look at Voxel and their LuxCreo printers.”

Ready to Upgrade Your Workflow?

Voxel Dental is the exclusive U.S. distributor of LuxCreo’s iLux Pro 3D printing ecosystem. If you're ready to ditch thermoforming, reduce production costs, and explore direct-print aligner technology, now is the time.

👉 Contact Voxel Dental to schedule a demo or get started today.