A method of laser cutting, comprising: creating a series of virtual specialised molds; creating a series of specialised molds (106, 206) based on the series of virtual specialised molds, each specialised mold of the series of specialised molds associated with a virtual treatment plan for incrementally moving teeth; wherein each mold is associated with a form factor of the mold during the treatment plan, each mold associated with a unique part within a respective portion of the virtual treatment plan and wherein each specialised mold is associated with a unique arrangement of teeth along a treatment plan for incrementally moving teeth; forming a respective series of sheets of material (208, 308) over the series of specialised molds, each sheet of the series of sheets conforming to respective molds of the series of specialised 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 specialised mold of the series of specialised 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 form the respective excess material along the cut path according to the instructions; and removing the respective dental appliance from each specialised mold. creating a series of virtual specialised molds; creating a series of specialised molds (106, 206) based on the series of virtual specialised molds, each specialised mold of the series of specialised molds associated with a virtual treatment plan for incrementally moving teeth; wherein each mold is associated with a form factor of the mold during the treatment plan, each mold associated with a unique part within a respective portion of the virtual treatment plan and wherein each specialised mold is associated with a unique arrangement of teeth along a treatment plan for incrementally moving teeth; forming a respective series of sheets of material (208, 308) over the series of specialised molds, each sheet of the series of sheets conforming to respective molds of the series of specialised 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 specialised mold of the series of specialised 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 form the respective excess material along the cut path according to the instructions; and removing the respective dental appliance from each specialised mold. 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 form the respective excess material along the cut path according to the instructions; and removing the respective dental appliance from each specialised mold.