This study investigated the use of shape memory polymers (SMPs) as an innovative material for orthodontic aligners to overcome the limitations of conventional multi-step staging. The research evaluated the ability of SMPs to recover their original shape and induce tooth movement when activated, using a typodont model as a preliminary in vitro test. The goal was to achieve a 1.9 mm movement of an upper central incisor using a single aligner through successive activation steps. A custom typodont with a movable central incisor was digitally scanned, and 3D-printed resin models were produced with orthodontic software. Seven aligners were then thermoformed from ClearX SMP sheets over the resin models. Each aligner’s capacity to reposition the central incisor was assessed on the typodont, and scans were taken after each step to quantify the movement via digital superimposition. The overall tooth correction reached approximately 93% (1.76 mm). Stepwise measurements showed 0.94 ± 0.04 mm after the initial reforming, 0.66 ± 0.07 mm following the first activation, and 0.15 ± 0.10 mm after the second activation. These results indicate that SMP-based aligners may offer a promising approach for aesthetic orthodontic treatments in the future.
