C64 Orthodontic Kit
The 3D, CNC Wire Former System For Orthodontic Professionals
Orthodontics embraced digital scanning years ago. But wire fabrication remained manual, dependent on highly trained technicians and difficult to scale.
The C64 Orthodontic Kit was developed to eliminate that bottleneck.
Pensa and Pensa Labs partnered to transform the last analog step in orthodontic production into a precise, scalable digital workflow, without removing technician oversight or control.
Awards
- IDEA - Medical & Health - 2025
- IDEA - Digital Interaction - 2025
- Design Value Awards (DVA) - 2025
- Innovation by Design Award - 2025
Services
The machines are straightforward and easy to maintain, without needing dedicated air or special-ordered spooled wire. The software is user-friendly and intuitive.
— Christian Saurman, CEO, NEOLab
From 3D Scan to Finished Wire
The solution integrates two components into a single system:
• The C64 precision CNC wire-bending machine
• WireWare Dt, orthodontic-specific design software
WireWare Dt enables technicians to design directly on patient scans using an interface that mirrors the logic of manual bending. The C64 translates those designs into accurate, repeatable bends, automatically compensating for material type and diameter.
Together, they create a seamless path from digital diagnosis to physical appliance, inside a compact bench-top footprint that fits existing lab environments.
Designed Around Real Lab Workflows
Technicians were co-creators throughout development. We observed lab environments, mapped friction points, and iterated through live production testing.
Design priorities included:
• Rapid onboarding
• Familiar workflow logic
• Real-time material compensation
• Reduced repetitive strain
• Preservation of technician quality control
The result is a system that reduces reliance on rare manual expertise while keeping judgment and oversight in the hands of the lab.
Where hand bending can take years to master, new users can produce consistent results from day one. Some labs reported 15 usable appliances from new hires on their first day, compared to 10 in three months using manual tools.
Scalable Performance, Measurable Impact
• 95% reduction in onboarding time
• 100+ appliances per day from experienced users
• Significant reduction in waste and rework
• Increased production capacity without proportional headcount growth
• Expansion of Pensa Labs into the professional orthodontics market
Labs can grow output without growing dependency on scarce talent. Technicians shift from repetitive execution to higher-value roles in design oversight and quality leadership.
Reinventing the Orthodontic Production Model
The C64 Orthodontic Kit is not just a machine. It is a redesigned production system.
By integrating hardware, software, and workflow design, the platform closes the gap between digital diagnostics and physical fabrication. It respects the craft of orthodontics while delivering the consistency, scalability, and resilience required for modern lab operations.