Abstract A method includes: receiving first and second digital models associated with a dental arch of a patient corresponding to first and second stages of orthodontic treatment; printing a first mold of a first dental arch based on the first digital model and a second mold of a second dental arch based on the second digital model; securing the first and second molds to a plate; heating a sheet of plastic to generate a heated sheet, and surrounding the sheet of plastic with a mask during the heating of the sheet of plastic to minimize heat transfer to other sheets of plastic; and simultaneously thermoforming the heated sheet over the first and second molds to form a first aligner shaped to fit the first dental arch and a second aligner shaped to fit the second dental arch.
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