Dental

The main applications of 3D printing in dentistry

One of the fields where 3D printing is gaining great popularity is dentistry. 3D printing in the dental sector is a tool that allows the creation of parts suitable for the needs and morphology of each patient. Whether it’s the use of resin additive manufacturing or powder bed casting, this manufacturing method opens up a wide range of possibilities for professionals in dental clinics and laboratories. In addition, dental 3D printing often goes hand-in-hand with other digital solutions, such as new CAD tools or dental 3D scanners used to capture the patient’s dental anatomy. In short, this ecosystem of new technologies brings a wide range of benefits to dentistry. But what are the real uses that we can highlight in this field, what technologies are integrated and for what purpose? In this list, we present the main applications of 3D printing and other technologies in the dental industry.

3D scanning in the dental industry

While this isn’t a dental 3D printing application per se, we couldn’t fail to mention 3D scanning. The use of 3D scanners is becoming increasingly common when it comes to 3D printing and dentistry. In fact, it’s one of the first steps in the digital workflow. Thanks to 3D scanners, healthcare professionals are able to digitize the inside of the patient’s mouth if they use an intraoral scanner, or digitize impressions using a laboratory scanner. This second solution is used in additive manufacturing. A digital footprint file is created that can be exported in STL format for 3D printing. That’s the how, but what about why? One of the benefits of using a 3D dental scanner is the accuracy achieved. It also gives the possibility to produce tailor-made devices, based on the exact morphology of the patient. In addition, if the patient needs an emergency prosthesis, for example, there is no need to make new impressions since these have been digitized. The patient saves time, as does the healthcare professional.

Crowns & Bridges

Dental crowns and bridges are some of the most common dental treatments as they are used to replace missing teeth. They are similar in many ways, but the essential difference between the two is that dental crowns are used to cover a damaged or decayed tooth, placing it on top of the damage. They can also plug dental implants in case there is no longer a tooth. Meanwhile, bridges are used to replace missing teeth, consisting of two crowns (one on each end) and then a denture bridge as needed. And, of course, 3D printing is playing an increasingly important role in dentistry. Temporary, highly accurate, and aesthetic Temporary, highly accurate, and aesthetic 3D printed crowns and bridges can be made using resin 3D printing. The technology is becoming increasingly popular because it allows for cheaper and faster production than traditional grinding processes. Although currently, 3D printed crowns and bridges are mostly temporary as dental resins are not as durable as zirconia, the technology is constantly advancing making it likely that this will change in the near future.

Aligners & Retainers

More and more dental devices are being produced with additive manufacturing, but it has not only allowed for a higher production speed but also greater customization, a very important aspect in this industry as every mouth is different. Now we will talk about retainers or “aligners”, devices used to prevent or even move patients’ teeth. To produce them, the process begins with a scan of the patient’s mouth, then CAD software is used and once the file is obtained we export it to the 3D printer that we are going to use. The most commonly used technology is resin 3D printing such as (SLA), (DLP) or (MSLA). Depending on your needs, you will use one technology or another. Then, the model is post-processed before being thermoformed.

Implants

Whenever we lose a tooth, this requires quick help through an implant, because otherwise the area around the missing tooth degrades due to insufficient stress. With the help of additive manufacturing, dental implants can not only be produced on demand and thus faster, but also customized. This is especially important in dental healthcare, as each person’s mouth and smile are individual. With the precise manufacturing method of 3D printing for dental implant surgery, patients are not limited in any way in terms of bite capacity or chewing function, for example. In addition, 3D printing is also considered a cheaper method that is constantly being improved through innovation and makes the production of dental implants much easier.

Surgical Guides

One particularly valuable use of 3D printing for dentistry of these is the surgical guide for dental implants. This is one of the latest advances and has revolutionized surgical processes beyond dentistry as well. For as long as dental implants have existed, it has been very difficult for dentists to place them in the right places. Due to the awkward angles and inability to see clearly, placement has been difficult for many dental professionals. As a result, many implants have been misplaced, which can lead to oral health complications. This is where surgical guides come in to address these issues. In particular, the guide helps dentists place dental implants correctly and in the right place. It is a single-use device designed to be placed directly on the patient’s teeth, and is equipped with a hole that allows an implant to be placed in the right place, at the right angle and depth. This method offers greater accuracy, about three times higher than manual positioning.

Replicas and anatomical models

Anatomical models are 3D representations of a part of the body, based on scans: for dentistry, this is the jaw or mouth. Models are used for the planning and discussion of surgical procedures, both patient-clinician and medical-clinician. They provide a detailed picture of the area of interest and can reduce the risk of operating errors as the dentist has a tangible anatomical structure to work on. But where does 3D printing come into play in dentistry? While traditionally it is possible to make a plaster model on which crowns and dentures can be placed, this is a slow and manual process and involves a waiting time before the model is ready. 3D printing can be used to produce the models, based on intraoral scans, quickly and efficiently as it is built layer by layer by the printer. Depending on the use of the model, different types of additive manufacturing are used. For basic models, FDM can be used with filament, but for more complex replicas, SLA is used to produce resin models. While the use of traditional gypsum-based methods is still common, 3D printing is becoming relatively popular for this purpose.

Denture

The use of 3D printing to produce dentures is an emerging technology that has the potential to simplify the process. While the traditional method of milling from a resin base is labor-intensive and involves several trips to the dentist, 3D printing could produce dentures more quickly and less expensively. Although the method is not currently perfect, limited by aesthetics and low-resolution printers, there have been a number of positive indications: recently, new materials for prosthesis production have been CE-marked (i.e., marked as safe for purpose in the EEA), and patient studies have suggested that the prostheses are acceptable to the user. Some companies, such as Formlabs, already offer custom prosthetic solutions; Their website suggests cost savings of more than half compared to fully milled teeth. The socio-economic impacts of additive manufacturing solutions are particularly intriguing, as we may see the application of 3D printing in the future to make prosthetics more available to those who need them most.

Casting Patterns

3D printing can also be used for indirect dental processes. While 3D printing is clearly used to make end-use parts for dentistry, including crowns and bridges, copings and substructures, and more, it also has a role to play in making castings. Dental fusion models are accurate, three-dimensional replicas of a patient’s teeth and can be used not only to study the mouth, but also to create crowns, fixed bridges, and dentures. Anyone who has had orthodontic work or been to the dentist has had the experience of biting into uncomfortable wax to create this perfect mold. However, with 3D scanning and printing, the process is streamlined, with a highly accurate mold created by printing, washing, and then removing unwanted supports, burnout, etc., giving a final product.