How to Design Bleaching Trays in iTero Design Suite/ Exocad (Full Step-by-Step Tutorial)

In this tutorial I walk through my complete workflow for designing bleaching trays in iTero Design Suite — from order setup all the way to a print-ready file. The same steps carry directly over to exocad, so whichever software you're running, you'll be able to follow along and design your trays in-house. I'm making a maxillary tray second molar to second molar and showing every setting I actually use. What you'll learn: ✅ Setting up the order and dialing in tray thickness (0.6 mm) ✅ Letting the AI segment the teeth — and how to correct it fast ✅ Skipping missing teeth so they don't get segmented ✅ Setting path of insertion and allowing undercuts (0.25 mm for Sprintray resins/printers) ✅ Freeforming facial space so the tray seats with room for gel ✅ Walking down the margins and fine-tuning them ✅ Exporting the bite splint CAD file to slice and 3D print ⏱ TIMESTAMPS 0:00 – Intro: Bleaching Trays in iTero Design Suite 0:14 – Order Setup & Tray Thickness (0.6 mm) 1:22 – AI Tooth Segmentation 1:52 – Correcting Segmentation & Skipping Missing Teeth 3:03 – Path of Insertion & Undercuts (0.25 mm) 3:40 – Block-Outs & Freeforming the Facial 4:58 – Checking Tray Space (~0.3 mm) 5:10 – Walking Down the Margins 6:27 – Finishing & Reviewing the Tray 7:06 – Exporting to Slice & 3D Print 👋 I'm Dr. Chance at Hunsaker Dental in Houston, TX. We design and produce all our appliances and restorations in-house, and I make these videos to help other dentists and labs get confident with digital workflows. 🔔 Subscribe for more iTero Design Suite and digital dentistry tutorials — trays, splints, crowns, onlays, and full chairside workflows. 💬 Questions about your own tray workflow, undercut settings, or print settings? Drop them in the comments — I answer every one. #iTeroDesignSuite #iTero #exocad #DigitalDentistry #BleachingTrays #CADCAM #Dentistry #DentalLab #3DPrinting #Sprintray