The clear aligner, commonly utilized in orthodontic treatment for malocclusion, necessitates the quantification of orthodontic forces, which is highly demanded by doctors for enhancing risk management and treatment efficiency. However, the current technology still faces obstacles in achieving conformal integration of pressure sensors onto clear aligners with large curvature for the quantification and real-time monitoring of orthodontic forces. In this paper, a conformal iontronic sensing clear aligner (CSA) is proposed based on flexible iontronic sensing mechanism, which conformally integrates the sensor with the aligner to quantify orthodontic forces throughout the treatment process while preserving the aligner's original function. Specifically, the ionic coating is seamlessly integrated onto the diaphragm by applying a layer of ionic paint before molding the clear aligner, while the sensing electrode array, designed using a kirigami-based structure, is seamlessly adhered to the ionic coating. By integrating the CSA into a dental model, its exceptional sensitivity and precise pressure mapping capabilities have been demonstrated. This enables the identification of various tooth movement patterns, discernment of orthodontic force magnitude, and continuous monitoring of forces throughout the orthodontic treatment. Consequently, this research is expected to significantly advance risk management, outcome prediction, and treatment efficiency in orthodontic treatments.
Clear aligners offer aesthetic and comfort advantages in orthodontics, yet their ability to deliver effective forces relies heavily on empirical judgment or large-scale optical scanning, lacking real-time quantitative evaluation. Integrating pressure sensors into aligners is a promising solution, but challenges in miniaturization, multi-dimensional sensing, measurement accuracy, and biocompatibility hinder clinical application. Here, an all-in-one Orthodontic Force Acquisition System (OFAS) is presented that enables real-time, 3D force monitoring using a cross-shaped iontronic sensing array and an origami-inspired, wireless battery-free readout circuit miniaturized for single-tooth placement. The system employs a cross-linked polyelectrolyte with low creep and high repeatability, achieving 1.14% measurement accuracy. A 15-day in vivo study demonstrates that OFAS accurately captured dynamic force profiles with strong correlation to tooth displacement (R 2 > 0.99), confirming its feasibility for real-time, quantitative orthodontic force measurement and enabling timely treatment adjustments.
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