The Virtual Articulator in Aligner Orthodontics

At a Glance

For Patients

To ensure the computer-based aligner planning corresponds to the actual jaw movement, a virtual articulator is used. This article explains how the real mandibular movement is digitally captured and incorporated into the planning.

For Professional Colleagues

Virtual articulator with digital motion recording (Digital Motion Decoder) in aligner planning.

Suitable Treatment at Our Practice: Digital Diagnostics

Function-Oriented Aligner Planning: When the Final Bite Is Included from the Start

Successful tooth correction means more than just straightening teeth. It is equally important that the teeth meet properly at the end and that the temporomandibular joints are relieved of stress. This article describes how a “virtual articulator” can be used to incorporate individual jaw movement into digital planning—and demonstrates this with a real treatment case involving temporomandibular joint symptoms.

Note: In 2025, a two-page German summary of this article was published in Quintessenz Zahntechnik. It presents the same treatment case in shorter form; the detailed version with all measurement steps can be found here. To the summary: The Virtual Articulator in Aligner Orthodontics – 2025 Summary.

What a Virtual Articulator Is

In computer-based aligner planning, the upper and lower jaws are virtually positioned in relation to each other. Until now, this was usually done using a rigid standard alignment that does not correspond to the actual opening and closing movement of the jaw.1 A virtual articulator, on the other hand, replicates the actual, individual jaw movement of the patient. This makes it possible to bring the bite into a healthy, joint-friendly position already during the planning phase.

Digital Joint Registration

To do this, the movement of the lower jaw is recorded using a digital measuring system. In the publication, this was the Dental Motion Decoder (DMD). Two small sensors, each weighing 3 grams, are temporarily bonded to two teeth in the upper and lower jaw and record 100 times per second how the jaw moves during opening, closing, and forward movement. After the measurement, they are removed again and the teeth are scanned.2 This data is then merged with the 3D scan of the teeth. The result: The orthodontist can see whether the temporomandibular joints have sufficient clearance3and can plan the aligners so that the bite ends up in a relieving position.

A Treatment Example

The Initial Situation

A 39-year-old patient presented with significant symptoms in the area of the temporomandibular joints (TMD – for temporomandibular disorder, often called TMJ) and worn front teeth. Her dental arches were asymmetric and narrow, individual front teeth were tilted, and the necessary support in the posterior region was missing. The digital joint measurement showed that especially the right temporomandibular joint did not have sufficient space.4 Clinically, the lower jaw deviated to the side when opening, the right joint showed crepitation and was tender to pressure in the back. In the recording, the movement path on the right was shorter, straight instead of curved, and showed jumps. For the planning, the joint position was therefore corrected downward by approximately 0.65 mm. For more on temporomandibular disorders, see our page on TMD treatment.

The treatment process

Based on the joint measurement, the bite was brought into a physiological position in the planning5 and the tooth movement was implemented step by step with clear aligners. The treatment comprised eight steps with two aligners each, first 0.5 mm and then 0.625 mm thick, made from the three-layer foil CA Pro, which we have described in an own professional publication. Small auxiliary elements on the teeth supported the planned movements. A front tooth that was no longer in the correct position was minimally adjusted in shape at the end.

The Result

After 16 weeks, the patient reported no longer having pain, and the subsequent follow-up measurement showed a healthy, physiological movement pattern of the temporomandibular joints once again.6 The teeth were positioned harmoniously in a stable bite. All molars were in contact again, and the planned contact point on the upper right incisor was exactly where it had been intended in the simulation. To maintain the result, she received a fixed retainer in the lower jaw and wears the final aligner at night in the upper jaw. This case represents an individual outcome; how quickly symptoms resolve varies.

What this case demonstrates

The combination of clear aligners and function-oriented planning with a virtual articulator makes it possible to achieve not only esthetic but also functionally healthy treatment results—especially in patients with temporomandibular disorders.

If no temporomandibular disorder is present, planning is based on the habitual bite position, according to the publication, and only the individual movement path is incorporated. If a disorder is present, a healthy joint position is first determined and planning is built on that foundation. At JUST KFO, we use the virtual articulator for temporomandibular disorders, teeth grinding, and function-oriented aligner planning. Aligners are a private service; statutory health insurance does not cover them.

A specific patient case on this: our treatment example Temporomandibular disorder (TMD) resolved with aligners