A method and apparatus form a tooth positioner for repositioning at least one tooth of a patient and provide a dental arch cast of a patient, separate at least one tooth from the dental arch cast, fix a pin in a stump part of the at least one separated tooth, and in any non-separated teeth, reconstruct the dental arch cast of the patient by aligning the separated teeth to correspond to the alignment in the patients mouth and hold the pins in a material that may be softened, soften the material, apply force to the pin fixed in the at least one tooth to be repositioned to move it in a desired direction to obtain a realigned arch, and form a tooth positioner corresponding to the realigned arch. The tooth positioner is used by having the patient wear it for a period of time.
