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

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1 February 2019 Carbon Digital Dentures: the 5-Stage, Step-by-Step Instruction Guide 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. PRINTED DENTURES, LIKE MILLED DENTURES, ARE A PROVEN SOLUTION THAT CAN MEET BOTH ESTHETIC AND ECONOMIC REQUIREMENTS. Photo Credit: Valerie McMillan, DDS

2 New Capabilities in 3D Printers 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. Digital 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. Stage 1: Nesting 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. 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. 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. The 5-Stage, Step-by-Step Instruction Guide 3

3 Printing Digital Dentures, continued Stage 2: Support Removal Stage 3: Bonding Stage 4: Polishing Stage 5: Composite Layering 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. 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. 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. 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. 4 The 5-Stage, Step-by-Step Instruction Guide Photo Credit: John McMillan, MDT The 5-Stage, Step-by-Step Instruction Guide 5

4 The Preferred 3D-Printed Denture Solution Subscription Model: the Time Has Come 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. Rapid technology shifts are forcing changes in the way we develop and consume products, services, and equipment. Distinct Advantages 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 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. 6 The 5-Stage, Step-by-Step Instruction Guide 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. Clinically proven Photo credit: Alexander Wunsche, CDT, President, Zahntechnique Alexander Wunsche, CDT, President, Zahntechnique 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. Subscription Features Regular over-the-air software updates Access to the latest materials and applications Avoidance of machine and technology obsolescence Data and analytics Service and support Preventive equipment maintenance No warranty or hidden fees The 5-Stage, Step-by-Step Instruction Guide 7

5 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. 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 Fast Printability, High Accuracy Powered 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. Carbon, Inc Mills Way Redwood City, CA dental@carbon3d.com carbon3d.com D-006 UPDATED