Dental appliances from multilayer films having discrete structures covered by an ion permeable release layer

A method for making a dental appliance configured to position at least one tooth of a patient, the method comprising:

• depositing a hardenable liquid resin composition on a major surface of a base polymeric material to form a pattern of discrete unhardened liquid regions thereon, wherein the hardenable liquid composition comprises a hardenable resin, a liquid carrier, and a therapeutic agent;
• at least partially hardening the unhardened liquid regions to form an array of structures on the major surface of the base polymeric material, the array forming a discontinuous layer on the major surface;
• forming an exterior layer comprising an ion-permeable polymeric material on the base polymeric material and the array of structures, the exterior layer being disposed over and in direct contact with both the array of structures and the base polymeric material;
• and
• forming a plurality of cavities in the base polymeric material to form the dental appliance, wherein the dental appliance comprises an arrangement of cavities configured to receive one or more teeth.