3D Printing in the Dental Marketplace

What differentiates various dental laboratory 3D printing solutions on the market? What new technologies and materials are becoming available, and which printers can offer those advances? Even laboratories that have already incorporated 3D printing need to continually assess advancements in hardware, software, materials, and post-sales support—and be ready to apply them to new products such as 3D-printed dentures.

Additionally, printer uptime is a critical factor for laboratory success. Downtime, through underuse or equipment failure, can complicate workflow schedules, result in revenue loss, and even damage client relationships. Understanding throughput needs, managing a dynamic workflow to fit production requirements, and monitoring equipment health is a constant process.

In response to these challenges, forward-thinking manufacturers like Carbon are developing innovative long-term partnerships and printer subscription models that specifically focus on the laboratory business and proactively address printing workflow needs and printer health through data and analytics.

Carbon Digital Dentures: the 5-Stage, Step-by-Step Instruction Guide

February 2019

PRINTED DENTURES, LIKE MILLED DENTURES, ARE A PROVEN SOLUTION THAT CAN MEET BOTH ESTHETIC AND ECONOMIC REQUIREMENTS.

Photo Credit: Valerie McMillan, DDS

Stage 1: NestingDigital Light Synthesis™ Technology. This breakthrough additive manufacturing technology was pioneered by Carbon. Fundamentally faster compared to other additive technologies in the market, Digital Light Synthesis enables users to manufacture durable, high-performance products at unmatched quality.

Continuous Printing with the M Series Printers. Carbon M series printers feature a build area that allows for larger parts, higher throughput, lower part cost, and high accuracy (often within +/-50 μm).

Improved Utilization with M2d Software. Laboratories with lower throughput requirements now have access to Carbon 3D print technology through a reduced size build area (M2d) as compared to the M2. As throughput demands increase, a simple software update enables the lab partner to double capacity by accessing the entire M2 build area—no downtime or need to subscribe to new or additional printers.

Over-the-Air Updates. Occurring every 6 weeks, these updates ensure the technology is constantly improving from day one. Carbon offers traceability, sterilization, and the ability to brand parts through advanced software and an IT infrastructure that adheres to regulatory compliance, GMP, and part traceability.

Printing Digital Dentures

While 3D-printed dentures are undoubtedly an exciting opportunity, their digital production will need to be implemented into the laboratory workflow appropriately to ensure success. Below are the five stages of printing digital dentures.

New Capabilities in 3D Printers

Technical Tips

As in milling, the printing process requires a balance between maximizing productivity and working within the equipment’s operating capabilities. In printing, a denture base benefits from orientations that minimize the amount of necessary supports while still maximizing the structural integrity of the part. This can be accomplished by nesting the part in either an angled or vertical orientation.

• Nesting involves arranging parts on the build plate to maximize throughput without sacrificing proper structural support.

• Parts should be sufficiently supported, using fence supports to stabilize long-span areas and post supports where surface area is limited.

• Orient parts so that supports will not contact critical surface areas, as this could hinder correct part functioning. Also, ensure the part is angled and supported so that all surfaces are supported to the build plate.

The 5-Stage, Step-by-Step Instruction Guide | 3

• Support removal is easiest prior to curing, as the material is softer at this stage.

• If the part is delicate, it is recommended to cure the part first and then remove supports after, which helps avoid part damage.

• Carbide burs, suitable for use with dentures, are recommended for the removal of supports post-cure.

• Denture polishing cones and wheels can also be used if greater smoothness is desired.

• To bond the denture base, fill the tooth sockets with enough denture base resin to ensure there are no gaps or air bubbles between the teeth and base.

• Gently press the teeth into the base and wipe away any excess resin that flowed onto the denture surface.

• Spot cure with a suitable UV curing light to set the teeth to the base.

• Once the base and teeth are spot cured, place the assembled denture into the curing unit and conduct the final cure according to the unit’s curing protocol.

Technical Tips

If a glossy post-cure finish is desired, use a brush to apply a thin layer of resin over the denture’s polish surface, or smear the resin by hand prior to the spot cure. This will result in a uniform, glossy post-cure surface that requires minimal polishing.

• Dentures should be polished using a lathe, muslin rag wheel, and standard denture polishing compounds.

• The use of a hand piece, bristle brushes, and polishing compounds help effectively polish tight spaces that cannot be reached with a lathe and muslin wheel.

• As an alternative to polishing, light-curing stains and glazes designed for use on composite and acrylic materials can be used to further characterize the final denture.

• If a highly characterized denture is needed, the use of layering composites is a great option.

• Using a carbide denture bur, cut back the denture base to the desired thickness and contour.

• Treat the denture base surface according to the composite manufacturer’s specifications and layer the composite to achieve the desired esthetic effects.

• Cure and finalize the composite according to the manufacturer’s recommendations.

Technical Tips

With printed dentures, there are no limits on characterization, which means that laboratories can combine the speed of Carbon’s printer with their own high-esthetic skills to provide an unrivaled denture solution.

Photo Credit: John McMillan, MDT

Printing Digital Dentures, continued

Stage 2: Support Removal Stage 4: PolishingStage 3: Bonding Stage 5: Composite Layering

The 5-Stage, Step-by-Step Instruction Guide | 54 | The 5-Stage, Step-by-Step Instruction Guide

Photo credit: Alexander Wunsche, CDT, President, Zahntechnique

“Printing 3D dentures on the Carbon printer is an exciting and excellent option for our laboratory—from traditional dentures up to immediate loaded implant solutions and prototypes. We are expanding our solutions and creating new opportunities by partnering with Carbon.”

— Alexander Wunsche, CDT, President, Zahntechnique

The Preferred 3D-Printed Denture Solution

As the first FDA-cleared Class II offering comprised of both a denture base and teeth, Carbon 3D-printed denture solution is blazing the trail for dental laboratories. With these materials, technicians can efficiently produce high-quality 3D-printed dentures using Carbon Digital Light Synthesis technology.

Subscription Model: the Time Has Come

Rapid technology shifts are forcing changes in the way we develop and consume products, services, and equipment.

In dental laboratories, workflow-critical technologies, such as 3D printers, demand innovative purchasing, service, and support solutions that maximize efficiency and prevent downtime. The Carbon subscription model for 3D printers is an industry-leading alternative, sparing laboratory managers the effort and expense of trying to future-proof their digital workflow on their own.

By creating a long-lasting partnership (instead of a transactional one), Carbon proves its confidence in the quality of its products and software, with all-inclusive service and support, free of charge.

Distinct Advantages

Subscription Features

• FDA-cleared base and teeth for final use

• Faster turnaround times

• Precise fit

• Optimized retention and comfort

• Fewer patient visits and less chair time

• Easy access to the patient’s digital file enabling fast replacement if damaged or lost

• Characterization is the same process for digital dentures as it is for milled

• Clinically proven

• Regular over-the-air software updates

• Avoidance of machine and technology obsolescence

• Preventive equipment maintenance

• No warranty or hidden fees

• Access to the latest materials and applications

• Data and analytics

• Service and support

The 5-Stage, Step-by-Step Instruction Guide | 76 | The 5-Stage, Step-by-Step Instruction Guide

Carbon, Inc.1089 Mills WayRedwood City, CA 94063+ 1.650.285.6307

dental@carbon3d.comcarbon3d.com

D-006 UPDATED 02.01.19

Fast Printability, High AccuracyPowered by Carbon Digital Light Synthesis™ technology, which features fast printability and high accuracy (often within +/-50 μm). If you are ready to learn how a partnership with Carbon can help transform your business to create great dental parts, please contact us at dental@carbon3d.com.

All-Inclusive Service + Support

Data + Analytics

World-Class Training +Education

Best-in-Class Reliability + Production

Consistency

Serialization + Traceability

of Parts

Simple, Validated Workflows

Comprehensive Partnership

Offering

Why Carbon

When we entered the dental market, our goal was to deliver a complete digital solution that always kept our customers on the leading edge with unparalleled uptimes and unprecedented service and support. We lead by offering high-value resins, regular software updates that improve the speed and accuracy of our hardware, and new validated workflows. We are proud to have collaborative, long-term partnerships with our customers. If you are seeking versatility and scalable growth with a true partner, look no further.