The production of regular dentures takes weeks of back-and-forth visits and multiple fittings. It also involves using goopy impression materials such as alginate that can make patients gag. On the contrary, 3D printing technology is fast becoming the preference for dental labs and clinics across the globe, and for a very good reason.
3D printing reduces production time from days to weeks with improved-fitting and more comfortable dentures. If you are a dental professional interested in upgrading your practice with this modern technique, knowing how to 3D print dentures means access to improved patient outcomes and efficient workflows.
What are 3d Printed Dentures?
3D printed dentures are customized dental prosthetics. Their production involves digital scanning, computer-aided design, and additive manufacturing technology. Unlike conventional dentures produced through impression-taking and manual molding, these dentures begin with exact digital measurements.
The process uses specialized dental resins that cure in 405nm UV light. This means that the dentures are built layer by layer at thicknesses of typically between 25-50 microns. How to 3D print dentures requires the use of digital scanning for precise measurement, CAD software for accurate design, and additive manufacturing for consistent production.
Another advantage of 3D printed dentures is biocompatible resins that have flexural strengths as good as or better than conventional denture base materials. Hence, 3d printed dentures provide durability for everyday function.
Advantages of 3d Printed Dentures
When you discover how to 3d print dentures, you get to know that speed is their biggest advantage. Regular dentures require 2-3 weeks with several patient visits, whereas 3D printed ones are ready in 2-3 days with a mere two appointments.
New intraoral scanners measure 15,000-20,000 data points per second, which produce accurate 3D models.
With 3d printed dentures, you will enjoy:
• Shorter turnaround times for patients
• Improved initial fit with fewer adjustments
• Less material waste up to 80%
• More similar results for different cases
• Improved patient comfort right from the first fitting
They are also cost-effective in the long run due to minimal material waste. As a technician, you can avoid multiple patient visits, enabling you to make more dentures per day with digital workflows.
How to 3D Print Dentures Step by Step
Learning how to 3D print dentures step by step enables you to adopt a digital workflow that guarantees precision and quality.
Step 1: Digital Impressions
First of all, the 3d printing denture system substitutes conventional impression materials with intraoral scanners that use structured light technology. These high-definition scanners let you scan your patient’s mouth. They also note the gum contours and anatomical landmarks that are very important for denture retention.
The scanning takes 10-15 minutes and produces a 3d model you can check immediately. This enables you to review full coverage of denture-bearing tissues and rescan areas that require greater detail.
Step 2: Denture Design
Next, you’ll use expert CAD software such as Exocad to convert the digital impression into a printable design. You can also show the virtual try-ins to patients with the suggested design in real-time, demonstrating aesthetics from various perspectives. This preview supports modifications that would be costly to make post-print.
Step 3: Printing
Then, dentures are printed using specialized dental DLP or LCD 3D printers. You will read the print file by orienting the denture design at optimal angles, mostly 15-30 degrees, to reduce support structures while maintaining correct resin flow.
Print time is 4-8 hours depending on denture size. Modern dental printers are able to print several dentures in parallel, optimizing production efficiency.
Step 4: Finishing
Then comes post-processing. The printed denture must be extensively cleaned in isopropyl alcohol to eliminate uncured resin before receiving its last UV curing in a dedicated light box.
Surface finishing requires polishing with conventional denture materials. 3d printed dentures generally need less harsh polishing compared to conventional techniques, allowing delicate anatomical details to be maintained.
Step 5: Final Fitting
The initial fitting appointment is about confirming digital accuracy. 3d printed dentures require minimal adjustments because of the precision workflow, but you will still check pressure points and border extensions with conventional assessment methods.
Aidite’s 3D Printing Denture System
Aidite provides an end-to-end solution that covers the entire digital denture process. Their system includes the A-IS Pro 3 scanner, Exocad software, EZPRINT-P1 printers, and resins.
A-IS Pro 3 Scanner
The A-IS Pro 3 can be used for scan types such as impressions, plaster models, and articulators. It can complete an occlusal scan in just 7 seconds. It captures small details that make a big difference in making dentures.
EZPRINT-P1 3D Printer
The EZPRINT-P1 incorporates DLP technology that is optimized for dental procedures. Its print speed is 36-72mm/h, and it prints consistent details such as tissue texture and border extensions that influence denture fit and retention.
Specialized Resin Portfolio
Aidite’s products have three resins for use in different stages of the workflow:
• TRY-IN Resin has convenient breakability for in-chair modifications
• Denture Base Resin ensures long-term dimensional stability and suitable flexural strength
• Crown Bridge Resin has high strength with Class IIa medical device certification
The system itself minimizes learning curves as compared to importing components from several suppliers, with the technical support encompassing the entire workflow.
Avoiding Common Errors in 3D Printing Dentures
Scanner calibration mistakes can ruin your entire process when you learn how to 3D print dentures. Regular intraoral scanner calibration is necessary to ensure accuracy, usually weekly or following major movement.
Insufficient border extensions, incorrect occlusal plane alignment, or inadequate tissue relief usually lead to ill-fitting dentures that need remakes.
Here are some common mistakes you should avoid when learning how to 3d print dentures:
• Skipping regular scanner calibration
• Inefficient print support structure design
• Incorrect resin storage leading to degradation
• Incomplete post-processing forming weak areas
• Hurrying design verification
3D printing failures usually occur due to incorrect orientation or poor support structures. Handling errors during materials impacts quality and safety, and they must be properly ventilated and disposed of.
FAQs Regarding 3D Printing Dentures
How to 3d print dentures step by step?
Begin with digital impressions with intraoral scanners, design on CAD software, print layer by layer with dental resins, finish with cleaning and UV curing, and finally finish the final fitting.
Where can I get 3d printed dentures?
Numerous dental clinics now provide 3D printed dentures. Search for providers with digital scanning options, certified dental 3D printers, and end-to-end digital workflow experience.
How are 3d printed dentures made?
They’re produced through scanning the mouth digitally, CAD software design, biocompatible resin printing with layer technology, and then finishing through professional polishing and adjustments.
How long does it take to 3D print dentures?
Real printing is 4-8 hours, but the entire process from digital impression to final denture generally takes 2-3 days with design and finishing steps.
Are 3d printed dentures as durable as traditional ones?
New dental 3D printing resins have a similar flexural strength to conventional materials if processed correctly, with more uniform properties throughout the prosthetic.
Wrapping Up
Mastering how to 3D print dentures is a huge leap forward for both you and your patients. The computerized workflow removes old manufacturing variables while giving you quicker, more precise outcomes with fewer patient visits.
Step-by-step 3D printing of dentures is possible with the right equipment, training, and workflow implementation. Your investment in digital denture technology, like Aidite’s 3d printing denture system, is rewarded with enhanced patient care, increased efficiency, and a competitive edge in today’s dental industry.