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Mia Aligners · The science & system

Mia Aligners, in clinical detail.

The tri-layer aligner sheet, the attachment library, the AI-amplified treatment-planning system, the manufacturing precision and the sustainable materials. The complete picture for clinicians who want to understand the product they’re putting in their patients’ mouths, and the production system standing behind every case.

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Designed & built in Cape Town

Designed, planned and manufactured locally.

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Industry-standard precision

99 µm print · 23% refinement rate.

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5.0 · 20,000+ cases across our team
iZi Flex Tri-Layer PRO, exploded layer stack Three co-extruded layers: PCTG outer skins and Lubrizol TPU core, bonded as one sheet. TRI-LAYER STACK True extrusion · no adhesive boundary Outer PCTG Clarity · tracking · shape memory BONDED Lubrizol TPU core Sustained force · low decay BONDED Outer PCTG Stain & crack resistance
iZi Flex Tri-Layer PRO solid aligner sheet

3 layers · 1 sheet | TRUE EXTRUSION · NO DELAMINATION

Explore the sheet detail
The aligner sheet

One sheet. Three engineered layers. Zero compromise.

Our aligners are thermoformed from iZi Flex Tri-Layer PRO, a true-extruded sheet where three engineered polymers are bonded into a single structure. Not laminated. Not glued. That’s why force delivery stays consistent over the wear cycle, and the aligner doesn’t delaminate, peel or craze in the mouth.

iZi Flex Tri-Layer PRO solid sheet and exploded PCTG and Lubrizol TPU layers
Zero Delamination

True-extruded as one solid structure

Consistent Force

Stable performance over the wear cycle

Better Comfort

Reduced initial pressure, predictable movement

Built to Last

Resists cracking, staining and daily fatigue

Outer layer · PCTG copolyester

High-clarity, stain- and crack-resistant copolyester engineered for shape memory. The layer your patients see, and the layer that keeps the aligner tracking on the planned arch form.

Buccal skin · clarity · tracking

Core layer · Lubrizol TPU

The mechanical heart of the sheet. Medical-grade thermoplastic polyurethane delivers controlled, sustained force with reduced initial pressure, better comfort, less force-decay, more predictable tooth movement between visits.

Mechanical heart · sustained force

Outer layer · PCTG copolyester (mirror)

Mirrors the buccal layer for symmetric force delivery. Resists deformation, cracking and fatigue under normal wear, including engagement over attachments and IPR sites.

Lingual skin · symmetric force
Tri-layer sheet · at a glance

What the structure delivers.

Four properties that matter when the aligner is in the mouth for two weeks at a time.

3-layer

True co-extrusion

Co-extruded structure, no adhesive boundary to fail

Low-decay

Force retention

Stable force retention vs. mono-layer PETG over 14-day wear cycle.

High clarity

Patient acceptance

Optical-grade copolyester outer skins for patient acceptance

15 min

Fresh thermoform

Every sheet thermoformed within 15 minutes of opening.

Attachment library · part of the embedded protocols

Four attachment families. Each earns its place on the tooth.

Mia’s attachment library is a controlled set of geometries inside our treatment-planning protocol, each one modelled and force-vector tested against a specific movement. We don’t decorate teeth. We use the smallest, smartest attachment that achieves the planned movement, and we remove it from staging the moment it’s done its job.

Horizontal attachment on tooth, extrusion, intrusion and vertical control
Horizontal

Extrusion · Intrusion · Vertical control

Workhorse attachment for vertical control. Broad flat surface delivers a clean force vector for vertical movements of bicuspids and incisors.

Vertical attachment on tooth, rotation, uprighting and torque
Vertical

Rotation · Uprighting · Torque

Engages cervically to deliver torque and uprighting moments. Used for canine rotations, posterior tip-back and premolar uprighting.

Stability attachment on tooth, anchorage, en-masse and retention
Stability

Anchorage · En-masse · Retention

Low-profile ellipsoid for controlled anchorage and retention. Default for posterior anchorage in retraction cases.

Mandibular extrusion attachment on lower tooth
Mandibular extrusion

Lower-arch extrusion & vertical control

Bevel-led attachment engineered for the bio-mechanics of extruding lower anteriors. Concentrates force occlusally without unintended rotational vectors.

Every attachment shape, position and stage in a Mia plan is reviewed by our clinical team before any aligners are produced, and justified against the planned movement. Less is more.

AI & planning platform

AI-amplified planning. Mia-shaped protocols.

The world’s leading orthodontic AI engine, running our team’s clinical playbook. SoftSmile Vision handles the heavy computational work, tooth segmentation, root estimation, collision modelling, movement-vector simulation. The decisions that matter clinically, staging logic, velocity caps, attachment placement, finishing rules, come from Mia’s own treatment protocols, written by working clinicians and refined across 20,000+ cases.

The engine

SoftSmile Vision · AI orthodontic platform

A world-class planning engine that turns intra-oral scans into segmented, simulatable arches in minutes. What the AI delivers:

  • Tooth segmentation, automated identification and parameterisation of every tooth from the STL
  • Root estimation, inferred root geometry for movement modelling, not just crown displacement
  • Collision modelling, interproximal contacts mapped across the planned trajectory
  • Movement-vector simulation, per-stage force vectors visualised for every tooth
  • Treatment-time prediction, data-driven case-length estimates calibrated to the chosen protocol
vision.softsmile.com →
The protocols

Mia treatment protocols · the clinical playbook

Built by working clinicians, the spine of every plan, applied on top of the AI:

  • Staging logic, movement sequencing rules written by Dr Petra van der Merwe across thousands of SA cases
  • Velocity caps, per-tooth, per-stage limits checked against published clinical evidence
  • Attachment placement rules, the four-family library mapped to movement type, not aesthetic
  • Refinement triggers, tracking thresholds that decide when to re-scan vs push through
  • Finishing rules, over-correction, IPR sequencing, retention strategy
Mia treatment planning preview: AI segmentation with Mia clinical protocol review

How they integrate

The AI does the computational work; the Mia protocols decide the clinical answer. Every plan is then reviewed by an HPCSA-registered clinician on our team before it ships to a provider. You will never approve a setup built purely by an algorithm.

Treatment planning pipeline

From scan to approved plan in five defined stages.

Same five stages on every case, first or fiftieth. The provider sees the plan, requests changes, and approves it. No plan ships without that loop closing.

STL in
Intra-oral scan

IOS scan upload (or impression-to-scan conversion). Scan-quality check runs immediately.

AI segment
SoftSmile Vision

Tooth segmentation, root estimation, collision modelling, movement-vector simulation in minutes.

Mia protocols
Our embedded staging

Velocity caps, attachment rules, finishing logic applied on top of the AI output.

Clinical team
HPCSA-registered review

Every plan reviewed and signed off by a working clinician before it reaches the provider.

Provider
Approval & clinical responsibility

The plan is shared with annotated views and notes. Provider approves, requests revisions, or escalates.

Dr Petra van der Merwe
Founding team · foundational protocols

Dr Petra van der Merwe · the protocols the AI was trained on.

A founding member of Mia and instrumental in bringing this product to market. The treatment-planning protocols, refinement policies and case-selection logic Petra built across thousands of South African cases still sit behind every Mia plan today, and were the training data the AI orthodontic tools we use have been shaped against. The technology is the leverage; her clinical playbook is the answer.

Product specifications

The numbers, in one place.

Materials, mechanical, manufacturing and clinical specs, for the clinician who wants the full picture before committing a patient to a treatment plan.

Aligner sheetMaterial
iZi Flex Tri-Layer PRO, true-extruded tri-layer thermoplastic. Outer skins: PCTG copolyester. Core: Lubrizol medical-grade TPU.
Sheet thicknessStandard production
0.76 mm typical, thinner and thicker variants available on case request for specialised mechanics.
Outer-layer polymerPCTG
High-clarity, stain- and crack-resistant copolyester engineered for shape memory and tracking precision.
Core polymerLubrizol TPU
Medical-grade thermoplastic polyurethane, controlled, sustained force delivery with reduced force-decay over the wear cycle.
BiocompatibilityCertifications
All polymers FDA-cleared for intra-oral medical use; ISO 10993 biocompatibility tested. No latex, BPA, or phthalate plasticisers.
Open-pack windowMaterial freshness
15 minutes from sheet pack open to thermoforming. Past that, the sheet is retired, no compromised material reaches a patient.
Print precisionDental-model production
99 µm layer height on Photocentric LC Magna 4K LCD printers, equivalent to the precision standard of the leading global aligner manufacturer.
Volumetric build accuracyLC Magna validation
±0.10% across the full build envelope. 98% of scanned points within ±0.10 mm of CAD.
Print resinDental-model material
Rigid DL240 Plant-Based, 50% biobased content, dimensionally stable post-cure, compatible with thermoforming pressures.
Attachment libraryGeometries
Four families: Horizontal (vertical control), Vertical (rotation/torque), Stability (anchorage/retention), Mandibular extrusion. All shapes force-vector tested.
Treatment planningAI + protocols
SoftSmile Vision AI engine running Mia treatment protocols (built by Dr Petra van der Merwe). Every plan reviewed by an HPCSA-registered clinician.
Refinement rateTrack record
23%, versus the 50% international industry average. At your volume the delta is the difference between margin and rework.
Plan-to-delivery turnaroundStandard cases
5 to 7 days from approved plan to aligners shipped. Local production, no overseas freight cycle.
Manufacturing pipelineProduction SOP
Eight defined operator roles. Batch traceability per patient. In-process QC at every stage, no aligner ships without final inspection.
RegulatorySouth Africa
SAHPRA-aligned manufacturing. HPCSA-registered clinical leadership. Plant-based resin compliant with EU and US dental-printing standards.
Manufacturing precision

A controlled, traceable pipeline from STL to packed case.

Every aligner is produced under a controlled SOP, eight defined operator roles and a traceable batch record on every patient. Industrial-grade 3D printing, calibrated thermoforming, final QC. A 0.1 mm error at the model doesn’t stay 0.1 mm in the mouth.

Case prep and STL export from approved SoftSmile Vision plan
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Case prep & STL export

Approved plan exported from SoftSmile Vision with stage naming, attachments, IPR notes and blockouts locked.

LC Magna 4K LCD dental model printing
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LC Magna 3D printing

Industrial 4K LCD printing in Rigid DL240 Plant-Based resin, ±0.10% volumetric accuracy across the full build envelope.

Photocentric wash and UV cure post-processing
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Wash & UV cure

Photocentric Air Wash and Cure L2 post-cure, full mechanical properties before any sheet touches the model.

BIOSTAR thermoforming and trimming Tri-Layer PRO sheets
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Thermoform & trim

BIOSTAR thermoforming with material-coded heat profiles. Tri-Layer PRO sheets thermoformed within 15 min of opening.

In-process QC inspection and batch release
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QC & release

In-process and final inspection, no aligner is packed without a QC pass and a batch record.

Manufacturing precision

The numbers behind the pipeline.

±0.10%

Volumetric accuracy

On LC Magna validation prints, across the full build envelope.

98%

Scan-to-CAD match

Scanned dental-model points within ±0.10 mm of CAD.

50%

Plant-based content

Biobased fraction in our Rigid DL240 dental-model resin.

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Operator roles

Distinct roles in the production SOP, each gated by a documented QC pass.

Proudly South African · Sustainable by design

Local pride and a lighter footprint.
Neither traded off against the other.

Mia is one of very few clear-aligner systems in the world that is locally designed, locally produced, and built on plant-based, recyclable manufacturing inputs. Two values that compound, pride in keeping the work here, responsibility for the country we work in.

Mia Aligners, designed and manufactured in Cape Town, South Africa
SA-owned, SA-built

Company, design, planning and production all happen in South Africa. Local employment, local supply chain, local clinical IP.

Plant-based dental model resin used in Mia Aligners production
50% plant-based resin

Our Rigid DL240 dental-model resin is 50% biobased, lower embedded carbon than conventional petrochemical resins, without sacrificing clinical accuracy.

Recyclable aligner production workflow at Mia's Cape Town lab
Recyclable production workflow

Cured models, sheet offcuts and packaging routed to recovery streams. Closed-loop where the polymer permits, downcycled where it doesn't.

Local Mia Aligners production, no overseas shipping cycle
Local production, smaller footprint

Aligners aren't shipped across two oceans. Local manufacturing cuts international freight emissions and removes FX shipping costs baked into every imported case.

The clinicians behind every plan

Built by working clinicians. Reviewed by working clinicians.

Every Mia aligner case is planned and approved by an HPCSA-registered clinician on our team. The system is designed by the people who use it, and the people who’ll plan your case are the people you call when something needs a second opinion chairside.

Dr Karishma Soni
Founder & Chief Dental Officer

Dr Karishma Soni

Mia co-founder, still running Mia Aligner cases in her own practice today. Drives the clinical standard with a passion for South Africa, aesthetic dentistry and serving her patients with the best possible treatments.

Dr Ismail Amra
Leading Orthodontist

Dr Ismail Amra

The latest addition to our team, stepping in as leading orthodontist after one of our founding members: Dr Petra van der Merwe, moved to Namibia. Brings a wealth of experience in both fixed and aligner treatments.

Adam Botha
Adam Labs · partner

Adam Botha

The doyen of South African ortho-lab products. Developed the country’s first aligner system with Dr Mark Bowes over 15 years ago, that depth of knowledge, case history and market-leading orthodontic-treatment integrations now sits behind every Mia case.

Bernice
Treatment planning

Bernice

Worked alongside Dr Petra for years on all her cases and became deeply specialised in the planning software, all the tricks and AI protocols that bring your smiles to life. Creative yet responsible, with the judgement to add real value to your practice.

Diyanah
Treatment planner · Adam Labs

Diyanah

Treatment planner out of the Adam Labs team. Day-to-day output, scan-to-plan workflow, attachment placement, staging, and the back-and-forth on plan revisions until it’s right.

Marietjie
Account coordinator

Marietjie

The person who keeps your account moving, onboarding, case status, refinement requests, peer-event invites and support escalation. The single point of contact when you need something done.

Technical questions clinicians actually ask

Into the detail.

What clinicians want to know before they commit a patient, materials, AI, certifications, the clinical safety net. If yours isn’t here, WhatsApp us and we’ll route you to the right person.

Both are thermoplastic copolyesters in the PET family, but PCTG (PET-G with cyclohexanedimethanol) has improved clarity, better impact strength, and superior crack resistance compared with standard PETG. In the Tri-Layer PRO sheet, PCTG forms the buccal and lingual skins because those are the layers patients see and the layers that have to resist daily fatigue. The mechanical heart of the sheet is the Lubrizol TPU core, not the outer layers: PCTG’s job is clarity and shape memory while the TPU delivers controlled force.

Mono-layer PETG aligners suffer from significant force decay over the 14-day wear cycle, force drops sharply in the first 24 to 48 hours and continues to decay through the wear period. Medical-grade thermoplastic polyurethane delivers sustained force with a much lower decay curve, which means more predictable tooth movement between visits and reduced initial pressure for the patient. Thicker PETG doesn’t solve the decay problem, it just makes the aligner harder to insert and more visible.

No. SoftSmile Vision handles the computational layer, segmentation, root estimation, collision modelling, vector simulation. The clinical decisions, staging logic, velocity caps, attachment placement, refinement triggers, finishing rules, come from Mia’s treatment protocols, written by Dr Petra van der Merwe and refined across thousands of SA cases. Every plan is then reviewed and signed off by an HPCSA-registered clinician on our team before it ships. You never approve a setup built purely by an algorithm.

All polymers in the iZi Flex Tri-Layer PRO sheet are FDA-cleared for intra-oral medical use and have been ISO 10993 biocompatibility tested. No latex, no BPA, no phthalate plasticisers. The Rigid DL240 plant-based dental-model resin complies with EU and US dental-printing standards for orthodontic-model production. Mia’s manufacturing operation aligns with SAHPRA requirements for a medical-device production facility, with HPCSA-registered clinical leadership over every case.

SoftSmile Vision is a world-class orthodontic planning platform that has been trained on a large clinical case base globally. What makes it Mia-specific is the protocols we run on top of it. Mia’s staging logic, velocity caps, attachment library and refinement triggers are encoded as the layer above the AI, effectively, our clinical playbook is the post-processing layer that turns a generic AI output into a Mia plan. Dr Petra van der Merwe’s protocols are the spine of every plan, and the AI is the leverage that lets us apply that playbook to your patient in minutes rather than hours.

On clinical output, Mia is at parity with the market leader on the dimensions that affect outcomes, 99 µm print precision, the same biocompatible material classes, every plan reviewed by an HPCSA-registered clinician. Mia’s refinement rate sits at 23% versus the 50% international industry average, partly because of the tri-layer sheet, partly because of the Mia protocols layered on the AI. Where Mia genuinely differs is in the relationship: direct WhatsApp to the planning clinician, 5 to 7 day plan-to-delivery from Cape Town, no quotas, and a partner that can’t pull out of South Africa because Cape Town is the only home we have.

Want to dig deeper?

Book a discovery call with one of our senior clinicians.

30 minutes. Honest conversation. We walk through the product detail, talk about your case mix, and decide together if Mia is the right fit. No pitch deck. No pressure.