A removable orthodontic appliance and methods of use and manufacturing of the removable orthodontic appliance for repositioning teeth of an upper jaw or lower jaw are provided. The removable orthodontic appliance comprises a trough shaped arch tray that defines an interstitial space between the sides of the arch tray for accommodating the teeth. The arch tray form fits over the contours of the teeth of the upper jaw or lower jaw from a first molar region through a second molar region. The arch tray extends down the teeth on a labial surface and a lingual surface of the teeth to the gingival areas. One or more arch wires are infused and rigidly anchored within the lingual side of the arch tray. Each of the arch wires comprises a surface pre-infused with a polymeric material for rigidly bonding to the lingual side of the arch tray.
