A Smile Transformed by Drs. Dustin Burleson and Brandon Simister

Orthotown Magazine 

Orthodontic treatment of cleft lip and palate patients using 3D printing and indirect bracket placement


by Drs. Dustin Burleson and Brandon Simister


Introduction
At the University of Missouri–Kansas City School of Dentistry, we have the privilege of treating patients through the Smiles Change Lives program. This case involved a patient with a cleft lip and palate, highlighting the vital role of advanced 3D technology in contemporary orthodontics. By integrating intraoral scanners, CBCT and 3D printers, we can ensure precise diagnosis, treatment planning and seamless collaboration with our craniofacial surgeons.

Our young patient presented with a concave facial profile because of a midface deficiency (Fig. 1). His maxillary teeth were in anterior crossbite, and there was a notable mucogingival defect around the cleft site. The cleft was quite large, adding to the complexity of the case (Figs. 2 and 3).
A Smile Transformed
Fig. 1a
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Fig.1b
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Fig.1c

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Fig. 2a
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Fig. 2b

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Fig. 2c
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Fig. 2d
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Fig. 2e
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Fig. 3


For orthodontic treatment, we planned to expand the maxilla and use a reverse-pull facemask1 and lower fixed appliances to correct the patient’s anterior crossbite. This comprehensive approach addressed the patient’s functional issues and improved their overall facial structure for better long-term results. The patient and his parent were made aware that, because of the underlying skeletal dysplasia, future orthognathic surgery is likely.


Case presentation
Cleft lip and palate can affect the alignment of teeth, development of the jaw and overall facial structure. Orthodontic treatment aims not only to achieve dental alignment and functional occlusion, but also to enhance facial symmetry and support overall oral health and speech.

Orthodontic treatment for cleft lip and palate patients is personalized and often requires a phased approach. Treatment often starts early, focusing on aligning the teeth and jaws before preparing for surgical interventions such as bone grafting. As the patient grows and develops, the treating orthodontist and craniofacial team determine the optimal timing for alveolar bone graft surgery. This ensures that the permanent lateral incisor or canine can erupt through the bone graft, facilitating proper integration and support of the repair.2

While most cases require similar foundational steps, such as expansion and alignment, 3D printing technology improves precision and outcomes. 3D printing has completely changed orthodontics since the late 1990s, allowing orthodontists to create custom appliances, surgical guides, splints and models with unparalleled accuracy.3 For this case, we used in-house 3D printers not only to assist with diagnosis and treatment planning, but also to communicate with the craniofacial surgeon, plan desired orthodontic eruption mechanics (Figs. 4 and 5), and fabricate splints and indirect bonding trays for bracket placement.
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Fig.4
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Fig.5

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Fig. 6


Treatment progress
Initially, we used a rapid palatal expander and instructed the patient to turn the expander one turn every other day for four weeks. This helped to begin the necessary expansion. Primary teeth within the cleft side were extracted after expansion (Fig. 6).

For alignment, 0.022-inch slot MBT (McLaughlin, Bennett, Trevisi) twin brackets were bonded on the maxillary and mandibular arches using Dibs by OrthoSelect segmented indirect bonding trays. The precision of digital bracket placement and CBCT imaging allows us to verify the UR1 root tip is positioned away from the cleft site. Before the bone graft, we created a customized splint using 3D printing and modification in conjunction with the craniofacial surgeon’s preferences. The timing of the bone graft was crucial, especially because the right permanent canine had a very thin or even absent bone on the mesial surface within the cleft. To prevent the graft from contacting the cementum or enamel surface, and because of delayed surgical timing and dental development, the graft was completed after partial canine eruption. See progress images (Figs. 7 and 8) for the CT slices before and two months after bone grafting, respectively.
A Smile Transformed
Fig.7
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Fig.8


We referred the patient for exposure of the impacted maxillary right permanent canine tooth (UR3), which was then brought into the arch.

After exposure, the UR3 erupted significantly on its own. We bonded an eyelet to the canine with a 0.13 overlay wire to help guide its position during orthodontic extrusion and with light traction from the distal, as planned in our virtual 3D workup. This highlights how 3D printing allows us to design and fabricate accurate models when treating cleft lip and palate patients so that indirect bonding trays and surgical splints can be tailored to our patient’s unique anatomy (Figs. 9–11).

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Fig. 9
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Fig.10
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Fig.11


  • Before the bone graft, we aligned the roots away from the cleft site to create an ideal site for graft integration and future tooth movement.
  • Intraoral scanners generate accurate digital models4 of dental and soft-tissue structures, eliminating the discomfort associated with traditional impression materials— an important advantage for patients with cleft lip and palate, who often have scarring, tight orofacial tissues and shallow vestibular spaces. Concurrently, CBCT imaging offers precise assessment and measurement of the bony clefts and facilitates detailed planning for orthodontic intervention and surgical preparation.
  • Using digital models created from intraoral scanners and CBCT images, we designed and fabricated custom palatal splints precisely tailored to the patient’s unique anatomy.
  • Indirect bonding trays allowed for accurate bracket placement, which is crucial for effective orthodontic treatment.
3D printing ensured better preparation for surgery, which might not be as finely tuned in cases without this technology. This enhances treatment outcomes and also contributes to a more comfortable orthodontic experience for patients.


Conclusion
At UMKC School of Dentistry, we employ a customized orthodontic approach using 3D technology that significantly enhances patient outcomes and quality of life, particularly in complex orthodontic cases. Through detailed treatment planning and the integration of 3D printing technology, we effectively addressed the intricate orthodontic needs of our patient.

We will monitor the stability of the achieved correction and measure continued jaw growth for possible orthognathic surgery in this challenging case, currently in the finishing stages of this phase of treatment (Figs. 12 and 13). Regular check-ups will be essential to maintaining progress and promptly addressing any emerging issues with relapse, speech and oral health related to the underlying cleft lip and palate.
A Smile Transformed
Fig. 12
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Fig. 13


Reference
1. Vaughn GA, Mason B, Moon HB, Turley PK. The effects of maxillary protraction therapy with or without rapid palatal expansion: a prospective randomized clinical trial. Am J Orthod Dentofacial Orthop. 2004; 128(3): 299–309.
2. Kim J, Jeong W. Secondary bone grafting for alveolar clefts: surgical timing, graft materials, and evaluation methods. Arch Craniofac Surg. 2022; 23(2):53–58.
3. Dawood A, Marti Marti B, Sauret-Jackson V, Darwood A. 3D printing in dentistry. Br Dent J. 2015 Dec; 219(11): 521–9.
4. Luu NS, Nikolcheva LG, Retrouvey JM, Flores-Mir C, El-Bialy T, Carey JP, Major PW. Linear measurements using virtual study models. Angle Orthod. 2012 Nov; 82(6):1098–106.


Author Bios
Dr. Dustin Burleson Dr. Dustin Burleson earned his dental degree and certificate in orthodontics from the University of Missouri–Kansas City and an MBA from New Charter University. Board-certified by the American Board of Orthodontics, he treats cleft palate patients at Saint Luke’s and Children’s Mercy Hospitals. Asdirector of the Leo H. Rheam Foundation for Cleft and Craniofacial Orthodontics and a provider for Smiles Change Lives, Burleson is dedicated to serving his community. He enjoys life with his wife and three children, and hobbies including cycling, golfing and sailing.



Dr. Brandon Simister Dr. Brandon Simister is a third-year orthodontic resident at the University of Missouri–Kansas City. Originally from St.George, Utah, Simister brings a unique perspective to orthodontics, drawing on the discipline and teamwork practiced as a former college basketball player. Simister is eager to continue to learn the latest research and techniques to implement into their future practice, while striving to create healthy, beautiful smiles for all patients.



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