I made an entire workflow with open source tools and materials that cost less than $100.
Here it is: https://www.youtube.com/watch?v=OfjuUN0E5yc
Like you said, the limiting factor is the extremely accurate scan. My workflow is not rigorous, just a proof-of-concept until the printing and scanning tech comes around.
Re:Straighter Teeth by Mail
by sethkontny on Friday February 13, 2015 @02:45AM
(#9043321)
sleepmedx
Part of the solution could be in home try-on (similar to Warby Parker). Ie send 10-20 sets of 3d printed retainers, all slightly different but potential fits. The customer selects which one fits best & the full set is based on that starting model. Since you're not actually creating molds to base the retainers on, the cost of each slightly different model should be pennies.
Anyway, that's about as far as I got... then I went back to building enterprise software.