Navigating Trade-Offs of Comfort and Efficiency
Through in-depth exploration, we realized Smile Direct’s challenges extended beyond pain management. They were creating treatment plans without fully understanding the dynamic interplay between teeth—moving one tooth impacts others in cascading ways that are difficult to predict. Addressing these complexities meant not only improving aligner efficiency but also ensuring the patient experience remained comfortable. Excessive pain could lead to customer dissatisfaction, cancellations, and revenue loss. By deeply analyzing these challenges, Ovyl helped Smile Direct craft a system that balanced precision, patient comfort, and business outcomes—leading to better treatment plans, improved customer retention, and a stronger market position.
Exploring Materials and Approaches
Building upon Smile Direct’s initial 3-tooth setup, Ovyl reviewed extensive research materials, patents, and reports. Through detailed discussions, the team identified key technical hurdles, including how to scale the system from 3 to 16 teeth. The team:
Researched and tested motor controllers capable of delivering precision down to 0.00005 mm increments.
Experimented with designs to achieve multi-axis movement, confirming that certain approaches weren’t feasible.
Selected and iterated on components that met the demanding requirements for precision and reliability.
Mechanical Design and Development
Ovyl designed and developed the mechanical system with a focus on delivering precision and reliability, which is crucial for meaningful data collection. To ensure stability and eliminate unintended movement, all mounted components were crafted from durable steel or aluminum. High-resolution linear actuators provided the exacting control required to limit variability and achieve accurate research outcomes. Recognizing the sensitivity of temperature fluctuations and air movement on test results, Ovyl also designed an acrylic cover to maintain a controlled environment while preserving visibility for users. This robust, carefully engineered system allowed Smile Direct to test a variety of aligner configurations effectively, translating sensor readings into actionable insights for treatment planning.
Custom Software
The software solution balanced automation and control. Ovyl developed algorithms that allowed for fully automated scripted control while also offering an expert user mode for precise adjustments. Thanks to built-in safeguards like force gauge monitoring, this dual-mode system empowered users to control forces on individual teeth without risking device damage.
