LightForce launches LightBracket Metal, first patient-specific 3D printed metal orthodontic bracket

LightForce Orthodontics has launched LightBracket Metal, a patient-specific 3D printed metal bracket that extends the company's individualized bracket system beyond ceramics into the segment accounting for 65% of orthodontic patients worldwide. The global orthodontic market is valued at $4.7 billion, and metal brackets are the dominant choice, especially among teenagers. LightForce's existing ceramic system has demonstrated a 60% reduction in appointments and a 43% reduction in treatment times compared to conventional braces. LightBracket Metal aims to deliver those same outcomes to the metal bracket market. The company operates what it describes as the world's largest facility for directly 3D printed functional medical devices by volume, using a proprietary metal 3D printing process (technology not disclosed). Rollout to practices is underway, with a public debut scheduled at the American Association of Orthodontists Annual Session in Orlando from May 1-3, 2026. CEO Dr. Alfred Griffin stated that the product changes the order of things by giving doctors the most exact instrument they have ever had.

This launch is a significant product extension within the medical-dental vertical, specifically orthodontics, where AM enables mass customization at scale. LightForce's approach—generating each bracket from the orthodontist's digital treatment plan across six parameters (base morphology, slot height, slot prescription, bracket position, tie wings, and hooks)—moves compensation for patient variation upstream into manufacturing, reducing chair time and manual adjustments. This is a direct application of the digital workflow integration that AM excels at, and it addresses a large, price-sensitive market segment that has historically relied on stock brackets. Competitors include traditional bracket manufacturers like 3M and Ormco, but LightForce's fully customized, 3D printed approach is unique. The move into metal brackets opens a much larger patient base than ceramics, and the company's existing FDA clearance and production facility provide a strong foundation for scaling.

From an AM industry perspective, LightForce's expansion into metal brackets is a logical and measured step. The key execution challenge will be scaling production to meet demand while maintaining cost competitiveness against mass-produced stock brackets. The proprietary metal AM process must prove its reliability and throughput in a clinical setting. For orthodontists, the value proposition is clear: reduced treatment time and fewer appointments. This is not a revolutionary leap but a solid product extension that demonstrates AM's ability to penetrate high-volume medical consumables markets with personalized production. The company's next milestone will be demonstrating consistent quality and delivery at scale.