Leone Rapid Expander Tooth Borne: A Modern CAD-CAM Solution for Skeletal Maxillary Expansion
Digital orthodontics continues to transform the way clinicians and dental laboratories design and manufacture appliances. One of the latest innovations from Leone Orthodontics is the Rapid Expander Tooth Borne, a CAD-CAM expansion screw specifically developed for digitally manufactured orthodontic appliances. Designed to combine precision engineering with a fully digital workflow, this appliance offers an efficient solution for rapid maxillary expansion while maintaining the reliability for which Leone expanders are known.
What Is the Leone Rapid Expander Tooth Borne?
The Rapid Expander Tooth Borne is the optimized CAD-CAM version of Leone’s well-established rapid expansion screw. Unlike conventional expanders, this model has been specifically engineered for integration with digitally designed and laser-manufactured orthodontic frameworks.
Its body features specially designed stop surfaces that enable accurate positioning during the digital design process. Once the framework has been produced using Selective Laser Melting (SLM) technology, the expander is permanently joined to the appliance through high-precision laser welding, ensuring an accurate fit and long-term mechanical stability.
Designed for the Digital Orthodontic Workflow
One of the greatest strengths of the Rapid Expander Tooth Borne is its seamless compatibility with the 3DLeone Designer software ecosystem.
The digital workflow typically includes:
- Importing STL files from laboratory or intraoral scanners
- Automatic positioning of the expander
- Digital design of customized bands, supports, and connecting arms
- STL export for Selective Laser Melting production
- Laser welding of the manufactured framework to the expansion screw
This guided workflow significantly reduces design time while minimizing operator-dependent errors, making digital appliance production more predictable and reproducible.
High Manufacturing Precision
Leone has maintained the same dimensions and clinical characteristics of its renowned expansion screws while adapting the product for modern digital manufacturing.
Key design features include:
- CAD-CAM optimized screw body
- Precision stop surfaces for accurate positioning
- Directional arrow laser-marked on the body
- Laser-engraved expansion scale in millimetres
- Clearly visible lot number for traceability
- High compatibility with laser-welded CAD-CAM frameworks
These details simplify both laboratory procedures and clinical identification while supporting consistent appliance fabrication.
Included in Each Package
Every Rapid Expander Tooth Borne package contains:
- 1 stainless steel expansion screw
- 1 blue activation key with handle
- Patient instructions for at-home activation
- Pack of one appliance
Multiple Expansion Sizes
The Rapid Expander Tooth Borne is available in several expansion capacities, allowing orthodontists to select the most appropriate device for each treatment case.
Available expansion models include:
| Order Code | Screw Width | Body Length | Expansion Capacity | Activation |
|---|---|---|---|---|
| A001043A | 12 mm | 8 mm | 8 mm | 0.8 mm |
| A001043B | 14 mm | 9 mm | 9 mm | 0.8 mm |
| A001043C | 16 mm | 11 mm | 11 mm | 0.8 mm |
| A001043D | 18 mm | 13 mm | 13 mm | 0.8 mm |
The appliance is designed to provide a maximum expansion of 35 to 60 quarter-turn activations, depending on the selected model.
Benefits for Dental Laboratories
For dental laboratories already working with CAD-CAM orthodontics, the Rapid Expander Tooth Borne offers several practical advantages:
- Faster digital appliance design
- Reduced manual soldering procedures
- Accurate and repeatable positioning
- Excellent compatibility with SLM-manufactured frameworks
- Reliable laser welding performance
- Reduced production errors through guided digital workflows
These features help laboratories improve productivity while maintaining high manufacturing standards.
Integration with 3DLeone Designer
The QR code included in the product documentation directs users to the 3DLeone Designer platform, Leone’s dedicated software environment for designing customized orthodontic appliances.
The software allows laboratories to:
- Import STL models from laboratory or intraoral scanners
- Access Leone’s complete CAD-CAM expander library
- Automatically position expansion screws
- Design customized bands and supporting structures
- Export production-ready STL files
- Integrate directly with Leone’s digital manufacturing services
The platform is available for both Windows and macOS and supports a complete digital workflow from virtual design to finished appliance production.
Conclusion
The Leone Rapid Expander Tooth Borne represents an important evolution in digitally manufactured orthodontic appliances. By combining Leone’s long-standing expertise in expansion screws with modern CAD-CAM design principles, the system provides orthodontists and dental laboratories with a precise, efficient, and highly reproducible solution for rapid maxillary expansion.
As digital workflows continue to become the standard in orthodontics, appliances such as the Rapid Expander Tooth Borne help bridge the gap between traditional clinical reliability and advanced digital manufacturing technologies.
Information Accuracy Disclaimer
Disclaimer: This article has been prepared for educational and informational purposes based on publicly available product documentation and manufacturer resources available at the time of writing. Product specifications, indications, availability, and technical details may change without prior notice. While every effort has been made to ensure the accuracy of the information presented, NOVI Dental Produkte GmbH cannot guarantee that all information is complete, current, or free from errors. Clinicians and dental laboratories should always consult the latest official documentation and instructions provided by Leone S.p.A. before selecting or using any medical or dental device.
