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REGGS SCHEU teeth aligner

ENGINEERING

Smart dental
solutions

DESIGN FOR SCHEU DENTAL

REGGS SCHEU red dot design award winner

THE ASSIGNMENT

Quadrupling efficiency and innovation

SCHEU Dental sought our expertise to design the Biostar® 4-Aligner, a semi-automated device capable of thermoforming four dental aligners simultaneously. This marked a significant leap forward from their previous manual device, which could produce just one aligner at a time. 

The goal? To revolutionise efficiency in the dental aligner industry.

Top view of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design
Scheu logo stripes
Sideview of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design

THE CHALLENGE

Intuitive design meets advanced engineering

Thermoforming dental aligners involves applying 4 Bar of air pressure to heated plastic sheets, generating immense force on the device’s structure. Our engineering team devised a compact, desktop-friendly solution featuring four automated pressure chambers, enabling users to save time and focus on other tasks.

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Once the proof of concept was successfully tested, the next hurdle emerged: how to ensure the device was not only safe but also intuitive and user-friendly.

THE RESULT

From innovation to award-winning design

The Biostar® 4-Aligner combines cutting-edge functionality with streamlined design. Its sloping front enhances user comfort and productivity, allowing effortless operation of the touchscreen while ensuring easy access to the foil plate and 3D-printed dental models on the model plate.

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The minimalist aesthetic integrates elegantly into the clean, professional environments of dental labs and orthodontic practices, reflecting SCHEU Dental’s commitment to innovation and precision.

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This pioneering design was recognised with the prestigious Red Dot Product Design 2024 Award in the Medical Devices and Technology category.

A testament to its transformative impact on the dental industry.

REGGS SCHEU red dot design award winner
Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design
Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design
Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design

Smart dental solutions

Project
Biostar® 4-aligner
Client
SCHEU-DENTAL
Market
Global
Award
Red dot design award
Services
Creative workshop
Innovation
Visual identity
Product design
Product engineering
Prototyping
Production support
Award
Red dot design award
More engineering
Technical detailed interior of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu
Technical detailed interior of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu

optimized airflow

easy to maintain construction

four automated pressure chambers

robust frame design with FE analysis

Technical detailed interior of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu
Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design
Technical detailed interior of Scheu Dental Biostar 4-aligner, Product design and engineering of Biostar 4-aligner for Scheu Dental, Red dot award winning medical device design
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