How Invisalign Became the World's Biggest User of 3D Printers

"Align is embarking on its biggest manufacturing overhaul since it was founded by two Stanford Graduate School of Business classmates 29 years ago. The company is preparing to begin directly 3D printing the aligners at the core of its business, ditching what Hogan describes as a longer, more wasteful process that involves making molds. A successful transition could lower costs and make treatment more affordable in the long run, bringing Invisalign to more customers and boosting Align's profits."

"It also, according to Hogan, would entrench Align as the world's biggest user of 3D printers. Hogan isn't a founder or a scientist, though he has raised honeybees for over 25 years. He also doesn't have a Wikipedia page, despite having run three multibillion-dollar international companies. But he's a manufacturing veteran who knows about plastics and 3D printing, especially after over a decade at Align."

"Shares of the company have tripled in price during his tenure as it outlasted failed upstarts and surged past other competition. Align handled a record 2.6 million cases last year, including a high of 936,000 kids and teenagers. Altogether, 22 million patients globally have worn Align's growing portfolio of aligners."

Align Technology, the $12 billion company behind Invisalign clear aligners, is undergoing its most significant manufacturing transformation since its founding 29 years ago. CEO Joe Hogan, a manufacturing veteran with over a decade at the company, is leading the shift from traditional mold-based production to direct 3D printing of aligners. This strategic overhaul aims to lower production costs, reduce waste, and make orthodontic treatment more affordable and accessible globally. The transition would establish Align as the world's largest user of 3D printers. The company processed a record 2.6 million cases last year, with 22 million patients worldwide having used Align's aligner products. Hogan has overseen significant company growth, with stock prices tripling during his tenure.

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