This article explores the advanced workflow involved in the direct printing of dental aligners, highlighting the significant features of Digital Aligner Design software. The study elucidates the step-by-step process from patient data acquisition to the final production of aligners, emphasising efficiency and precision. Using case reports, the present authors demonstrate the practical application of Digital Aligner Design software, which incorporates algorithms for optimal tooth movement planning and aligner design. The software’s interface and robust features facilitate easy integration into clinical practice, ensuring enhanced patient outcomes. The case reports presented illustrate the capability of unique aligner features in addressing diverse orthodontic challenges, showcasing their adaptability and effectiveness in real-world scenarios. Keywords: direct printed aligners, shape memory polymers, workflow