Joe Hogan, the CEO of Align Technology, is steering the company through a significant transformation as they prepare to directly 3D print their famous Invisalign aligners. This shift marks the most substantial manufacturing change in Align’s nearly three-decade history. Previously, the company relied on a complex and wasteful mold-making process. By embracing 3D printing, Align aims to reduce costs, increase accessibility for customers, and fortify its position as the world’s largest user of 3D printers.
During Hogan’s tenure, Align’s share price has tripled, and they processed a record 2.6 million cases in one year, with a growing number of children and teenagers seeking treatment. Align oversees the entire process of orthodontic care, developing the scanners, AI software for treatment planning, and the machines for manufacturing the aligners. Hogan predicts continued growth as the company refines its production capabilities.
In a conversation at their Silicon Valley lab, Hogan reflected on his personal experience with Invisalign. He emphasized that while he doesn’t wear his retainers nightly, many patients should prioritize their long-term dental health. He explained that Align holds a sizable market share in the clear aligner sector, and their revenue reflects their dominance in orthodontics, outpacing traditional braces.
Hogan attributes Align’s success to pioneering mass customization in 3D printing technology, allowing the company to produce millions of unique aligners daily. His insight stems from years of refining complex processes, positioning Align ahead of competitors who struggled to scale.
Align’s 3D printing process is extensive, and Hogan asserts that they are the top consumer of these machines worldwide. The company faces challenges in transitioning to printing aligners directly, mainly due to complex material requirements that differ from previous mold-making techniques. Hogan has plans to produce a new resin that will offer the same benefits as their existing materials, facilitating direct 3D printing of aligners.
As Align expands into new markets, including Asia and the Middle East, the company is actively adapting its technology to meet diverse dental needs. Hogan acknowledged a growing trend toward functionality in orthodontics, with both aesthetic and medical concerns driving patient decisions.
Pricing remains a contentious issue in the North American market, influenced heavily by the dental insurance landscape. Align charges doctors for each case based on the number of aligners needed, but final consumer costs can vary based on orthodontic practices.
Hogan also addressed common patient issues, such as the risks of eating with aligners, which can lead to cavities and tooth discoloration. He stated firmly that patients should not eat while wearing their aligners, stressing the importance of following dental advice.
Overall, Align is positioned for significant growth and innovation as it builds on its expertise in 3D printing and orthodontics. The company’s future thus rests on effective scaling of their new processes, which will help make their aligners more accessible to a wider range of patients.
