Systems, apparatuses and methods for dental appliances with integrally formed features

A system comprising:

• one or more processors configured with instructions to:
• determine a movement path to move one or more teeth from an initial arrangement to a target arrangement and generate one or more intermediate arrangements for repositioning the one or more teeth from the initial arrangement to the target arrangement;
• determine an appliance geometry for one or more aligners, wherein each of the one or more aligners comprises a shell and one or more integrally formed components joined to the shell, wherein the shell comprises a plurality of teeth receiving cavities shaped to move the one or more teeth according to a respective intermediate arrangement, wherein a placement of the one or more integrally formed components within the shell is determined based at least in part on the respective intermediate arrangement, and wherein the one or more integrally formed components comprise an elastic, a wire, or a spring, and the elastic, the wire, or the spring is used as an arch expander, a palatal expander, or a palatal bar;
• and
• generate instructions for direct fabrication of the one or more aligners, wherein the instructions include a first digital representation of the shell of at least one aligner and a second digital representation of the one or more integrally formed components of the at least one aligner, and wherein the instructions are configured to cause direct fabrication of the shell of the at least one aligner using a first material and direct fabrication of the one or more integrally formed components of the at least one aligner using a second, different material;
• and
• a fabrication machine configured to:
• receive the instructions for direct fabrication of the one or more aligners;
• and
• directly fabricate the one or more aligners by fabricating the shell of the at least one aligner using the first material and based on the first digital representation concurrently with fabricating the one or more integrally formed components joined to the shell using the second material and based on the second digital representation, wherein directly fabricating the one or more aligners comprises building the shell of the at least one aligner and the one or more integrally formed components of the at least one aligner together by extruding at least one biocompatible polymer in a layer-by-layer fashion.