A method of making a dental appliance for repositioning a patient's teeth includes: providing a target dental model of the patient's dental arch in a target tooth arrangement, and providing a combined dental model derived from the target dental model and an initial dental model of the patient's dental arch in an initial tooth arrangement； forming a block-out layer to cover at least one first tooth of the combined dental model； forming a first material layer over the block-out layer and the combined dental model to form a rigid shell； forming a second material layer over at least one first tooth of the target dental model corresponding to the at least one first tooth of the combined dental model； placing the rigid shell against the second material layer and the target dental model to form at least one resilient member in the rigid shell.
