Plastic Orthodontic Aligners – Burnish, Deburr

A dental customer needed to remove sharp burrs from the trimmed edges of formed acrylic orthodontic aligners without clouding or hazing the clear surface. The deburring process had to round and smooth all exposed edges to ensure patient comfort, while maintaining full transparency of the aligner body.

Bel Air developed a multi-stage finishing process using both high- and low-energy systems to gently deburr and burnish the edges of form-trimmed orthodontic aligners. Vibratory and centrifugal systems were used with media and compounds tailored to preserve optical clarity while softening edges. The result was a clean, smooth finish with no visible haze—improving patient comfort and eliminating the need for manual hand-trimming.

If you are unsure what equipment and media you require to achieve your desired surface finish, then send us your part, and we will evaluate it and provide you with a metrology report.