Cost-cutting is a reality in any business, but in orthodontics, opting for the cheapest available appliances is rarely a sound financial decision. A poorly made orthodontic appliance doesn’t just lead to minor inconveniences—it can disrupt treatment plans, increase chair time, and frustrate patients and parents. Over time, these inefficiencies drain revenue and weaken a practice’s reputation.
Studies show that inefficient workflows and treatment disruptions are among the top concerns for orthodontic professionals (American Association of Orthodontists). While a high-quality orthodontics lab ensures precision and reliability, budget-focused labs frequently produce orthodontic appliances that require costly adjustments or complete remakes, erasing any perceived savings.
Says OrthoDenco managing partner Rene Silva, “If you are an orthodontist who is looking for economic efficiency and savings in your practice, you might be tempted by some of the lower-cost orthodontics appliances in the market. But that cost ‘saving’ can become very, very expensive in the long run. There is a big difference between less costly and cheap,” he continues, adding that poorly-built appliances result in less than ideal patient outcomes. “And that leads to unhappy patients, who will not be coming back to you and who certainly will not be referring their friends, family, and acquaintances to your clinic. Bad outcomes for patients mean bad outcomes for orthodontists, too, “ he concludes.
We’ll break down the real costs of going with cheap orthodontic appliances and show why investing in quality pays off—in both your finances and patient care. You don’t have to break the bank to get the best possible orthodontic appliances for your patients. You just need the right lab partner – not a provider or a vendor, but a true partner who cares about your success as much as they care about theirs.
What Happens When You Choose a Low-Cost Orthodontics Lab?
A lower-cost orthodontics lab may seem attractive on paper, but these providers often cut corners in materials, fabrication processes, quality control, and customer service. The result? More headaches for you, your team, and your patients.
Increased Risk of Remakes and Adjustments
Precision is non-negotiable in orthodontics. Even a 1mm discrepancy in an appliance fit can disrupt treatment progress, requiring additional appointments and adjustments. Research in the Journal of Clinical Orthodontics found that remakes account for up to 8% of all orthodontic appliance orders, and that number is significantly higher when working with lower-tier labs (JCO Online).
When an appliance doesn’t fit:
- Valuable chair time is lost making adjustments.
- Patients experience discomfort, lowering compliance.
- Extended treatment timelines lead to frustration and increased no-show rates.
Instead of focusing on new patient consultations and case starts, your team spends unnecessary time correcting avoidable errors.
Poor-Quality Materials Lead to Fractures and Failures
Not all orthodontic materials are created equal. Cheap acrylics, substandard wires, and low-quality digital prints result in fragile appliances prone to breaking.
For example, thermoformed clear aligners produced with inferior plastics tend to lose shape quickly, requiring replacement trays that increase lab costs over time (Dental Materials Journal). Similarly, retainers fabricated with low-grade acrylics and wires are more likely to crack, leading to frustrated patients and additional lab orders.
Common problems associated with low-quality materials:
- Retainers and aligners losing retention within weeks.
- Expansion appliances cracking under normal stress.
- Lingual arches and space maintainers failing prematurely.
Delays That Disrupt Treatment Schedules
Orthodontic treatment is a meticulously planned process, often mapped out over 12 to 24 months. Any disruption to this timeline can cause significant setbacks. Cheap labs frequently lack streamlined production systems, leading to delayed shipments and unpredictable turnaround times.
According to an industry report from Dental Economics, practices that experience consistent lab delays report increased patient dissatisfaction and scheduling inefficiencies, which ultimately hurt growth and profitability (Dental Economics).
Late appliance deliveries cause:
- Increased chair time when patients return for follow-ups without the necessary appliances.
- Extended treatment durations when adjustments get pushed back due to appliance delays.
- Erosion of patient trust as parents begin questioning your practice’s reliability.
Limited Customer Support and No Customization Options
Many budget orthodontic labs operate on a high-volume, low-margin model, meaning they lack the flexibility to accommodate special requests or correct errors efficiently. If an appliance arrives incorrect or damaged, your team may find it difficult to reach a knowledgeable technician—or worse, they may receive no assistance at all.
Signs of a lab that doesn’t prioritize customer service:
- No direct communication with lab technicians.
- No case tracking or real-time updates.
- No ability to make case-by-case modifications.
A lab that values relationships over volume will offer direct communication, quick problem resolution, and tailored solutions for complex cases. This is the difference between a lab that serves your practice and one that simply processes your orders.
The True Cost of Cheap Appliances
At first glance, a low-cost orthodontics lab may appear to save your practice money. But over time, these hidden costs add up:
Increased Chair Time = Higher Operational Costs
Every time an appliance needs an adjustment, remake, or repair, your practice loses efficiency. If your team spends an extra 10 minutes per patient fixing poorly made appliances, that’s hours lost per week—time that could have been allocated to new consultations or value-generating procedures.
According to the American Dental Association (ADA), inefficiencies in patient scheduling and excessive chair time reduce profitability by up to 15% annually (ADA Research).
Patient Dissatisfaction Leads to Fewer Referrals
Word-of-mouth referrals remain the largest driver of new patients for orthodontic practices. When treatment is delayed or appliances break, patients and parents lose confidence in their provider.
- 86% of patients say treatment delays impact their satisfaction with their orthodontist (American Journal of Orthodontics and Dentofacial Orthopedics).
- More than 60% of patients will leave a negative online review after repeated issues with their appliances (BrightLocal).
Investing in high-quality appliances prevents these issues before they start, protecting your reputation and encouraging positive reviews and referrals.
Says Rene Silva, “At OrthoDenco, one of the questions we are always asking ourselves is ‘how do we help the orthodontists and pediatric dentists who rely on our orthodontics lab improve their own practices?’ The doctors who work with us after having been with a different lab consistently tell us that the peace of mind they get from knowing we’re going to be on time, with the highest quality appliances exactly to their specifications, improves their day-to-day operations.”
This leads to greater patient retention, a positive reputation through word of mouth (and online reviews), and more referrals for orthodontists and dentists who choose OrthoDenco as their orthodontics lab.
Long-Term Revenue Loss from Poor Retention
Patient retention and referral rates directly correlate to treatment satisfaction. If your practice develops a reputation for frequent appliance failures or treatment disruptions, parents and adult patients will seek care elsewhere.
A study in Dentistry IQ found that practices with consistent lab-related complaints see a 20% decrease in retention over three years (Dentistry IQ).
Why Investing in a Quality Orthodontics Lab Saves You Money
A high-quality orthodontics lab isn’t just a vendor—it’s an extension of your practice. Working with a reputable lab means:
- Fewer remakes and adjustments, reducing chair time.
- Reliable, on-time deliveries that keep treatment schedules intact.
- Stronger materials and better fabrication techniques, leading to fewer failures.
- Direct access to skilled technicians for case customization and troubleshooting.
At OrthoDenco, we focus on precision, reliability, and white-glove customer service. Every orthodontic appliance is fabricated with top-tier materials and rigorous quality control, ensuring that it fits correctly the first time. We don’t just fulfill orders—we partner with orthodontists to improve patient outcomes and practice efficiency.
Protect Costs Without Compromising Quality
A lower-cost orthodontic appliance isn’t cheaper if it increases your chair time, damages your reputation, and frustrates your patients. The real value in orthodontics comes from consistency, accuracy, and long-term reliability.
If your current lab isn’t delivering on time, producing quality work, or supporting your practice, it’s time to make a change. “I can promise you, you will see the difference quickly when you work with us,” says Rene Silva. “We love what we do, and we love the peace of mind we’re able to bring our customers – and their patients.”
Contact OrthoDenco today and experience a lab that works for you—not against you.