Orthodontic appliances having improved bonding characteristics and methods of making such orthodontic appliances are disclosed. The appliances to which the present invention is applicable have a metal bonding base and tooth contact surface. Primary mechanical interlock retention means or surface is applied to the tooth contact surfaces. The primary retention surface may be 1) a mesh, 2) a layer of metallic or non-metallic particles (such as spheres, rods, shards, etc.), or 3) grooves, including undercuts, formed in the tooth contact surface. The appliances preferably further comprise secondary mechanical bond strength enhancement means or treatment. Suitable secondary enhancement treatments include 1) surface roughening (e.g., ion bombardment or other etching processes), 2) particles on the order of 5-200.mu. flame spray coated on the primary retention surface, and 3) a chemically activatable material, such as SiO.sub.2 deposited on the primary retention surface. Chemical activation may also be used to activate the chemically activatable material, such as silanation of SiO.sub.2.