A method comprising providing a series of specialized molds, each specialized mold of the series of specialized molds associated with a virtual treatment plan for incrementally moving teeth； forming a respective series of sheets of material over the series of specialized molds, each sheet of the series of sheets conforming to respective molds of the series of specialized molds to create a series of conformed sheets of material, the series of conformed sheets of material forming a respective series of dental appliances associated with the virtual treatment plan and a respective series of excess material to be removed from the series of conformed sheets of material； for each specialized mold of the series of specialized molds: defining a cut path for removing the respective excess material from the respective conformed sheet of material； formulating instructions to guide a laser from a laser generating component to cut through the respective conformed sheet of material along the cut path； trimming, using the laser, the respective conformed sheet of material to separate the respective formed dental appliance from the respective excess material along the cut path according to the instructions； and removing the respective dental appliance from each specialized mold.
