Revolutionizing Dentistry: 3D Printing Applications & Material Innovations

3D printing, or additive manufacturing (AM), has become a fixture in dental offices and practices around the world. Dental 3D printing creates dental parts for dentists as tools or fixtures to print parts and for patients to use. These parts can range from models of teeth and dental aligners to full sets of dentures. In the past, dental providers used scans, radiology, and teeth molds to obtain accurate images of patients’ teeth. These images were then used to construct special, tailored implants for the patient. Now, with 3D printing, dental providers can both create more specialized implants and treat patients more rapidly.

Dental 3D printing makes use of all types of AM technology, including digital-light processing (DLP), selective laser melting (SLM), stereolithography (SLA), and selective laser sintering (SLS). 3D printing not only makes life easier for dental providers but also delivers significant benefits to patients: customized, affordable dental solutions.

In this article, we dive deeper into 3D printing in dentistry - from its history and first uses in dentistry, to current applications and uses - to give you a better understanding of how it has impacted the practice.

What Is Dental 3D Printing?

Dental 3D printing is the use of additive manufacturing to create dental parts such as aligners, dentures, and crowns. To create custom parts that match a patient’s anatomy, dental providers use a tool called an intraoral scanner. This creates images of a patient's teeth and records them in the form of a CAD file. Dentists then use this CAD file to create implants or dental molds through 3D printing. In the past, creating dental implants and molds was a cumbersome, invasive, and sometimes uncomfortable procedure. 3D printing has significantly simplified and improved the work of treating patients.

To learn more about how 3D printing works, see our guide on 3D printing.

What was the First 3D Method in Dentistry?

The concept of 3D printing in dentistry first arose in 1971 as “digital dentistry.” In digital dentistry, dental providers used CT scans and other computer-based analyses to diagnose patients and assist in surgery. It wasn’t until 1999 that 3D printing, as we know it today, really took hold in dentistry. At that point, it saw its first use in creating custom implants for patients. Today, continued advancements in 3D printing enable both faster turnaround and more accurate dental prints.

How is 3D Printing Used in Dentistry?

3D printing is used in dentistry to obtain accurate images and models of the anatomy of a patient’s teeth and jaws. An intraoral scanner captures the exact anatomy of a patient’s mouth. The data from the scan is then used to construct a 3D-CAD model of the desired anatomy. The CAD file, once completed, is uploaded to a 3D printer and built. Dentists can go through several iterations before they obtain a model that is both accurate and comfortable enough for the patient.

Using an intraoral scanner and corresponding images, dentists can also print surgical guides that help during an operation. This enables safer surgery, faster healing, and added prosthetic comfort.

Check out our Dental 3D Printing Service for an instant quote.

What Material is Used in the 3D Printing of Teeth?

Materials used in dental 3D printing are not the same as those typically used in 3D printing of other industrial products. Dental 3D printing materials are designed specifically for biocompatibility, aesthetics, and safety in dental applications. Certain resins are explicitly used for anatomical models and replicas (referred to as model resins). Others are designed for implants (draft and castable resins). Additionally, there are resins that are used for creating temporary dental appliances, resins that print clear for use in creating mouth guards, and resins that resemble gingiva for use with dental implants.

Depending on the manufacturer, resins can have different chemical compositions. There is no prescribed standard for dental 3D printing materials, however. Dentists usually select the material they think is best for the patient's dental application. If several appropriate choices exist, they may discuss them with the patient.

How are 3D Printed Dentures Created?

Below is a simplified step-by-step procedure of how dentists create 3D-printed dentures:

Obtain a digital model of the dentures to be printed. This can be done by creating a 3D-CAD file via an intraoral scanner.
Choose a suitable material for the dentures.
Print the dentures with the chosen material based on the created CAD file.
Remove any support material from the dentures.

How Long can 3D Printed Dentures be Worn?

3D-printed dentures can be worn in the same way as normal dentures. They should be removed and cleaned with a denture cleaner daily. They should also be kept moist in a secured case when not in use. 3D-printed dentures can be expected to last about 5-7 years before possibly needing replacement.

Frequently Asked Questions About 3D Printing in Dentistry

Can Dentists 3D Print Crowns?

Dentists can 3D print crowns. The traditional method of making crowns was remarkably slow and costly. 3D printing has enabled the creation of highly accurate crowns in a fraction of the time compared to traditional manufacturing methods. This saves time and money for dentists, allows for easy customization, and enables the creation of comfortable, long-wearing crowns.

What Materials are 3D Printed Crowns Made of?

Some 3D-printed crowns are made of ceramic, castable waxes, and 3D printable resins. Castable waxes and resins are composed of about 20% wax. The wax is what helps the crown stick to the patient’s mouth and helps the crown have a similar density as actual teeth. For 3D printed crowns, however, many of the chemical compositions of materials, are proprietary and vary from company to company. The technical data sheet of the resins should be reviewed.

How Long Does 3D Printing a Dental Model Take?

3D printing of dental models is significantly faster than creating dental models through traditional methods. On average, it takes about 2 to 2.5 hours to 3D print a dental model.

How Much do Dental 3D Printers Cost?

3D dental printers range from a few thousand dollars for small, desktop printers to tens, if not hundreds of thousands of dollars for larger systems. Prices mostly depend on print quality, build volume, 3D software, and repeatability. As a dental provider, decide which factors, such as, quality, build volume, cost, etc. are most important to you and pick a suitable printer.

Dean McClements

Dean McClements is a B.Eng Honors graduate in Mechanical Engineering with over two decades of experience in the manufacturing industry. His professional journey includes significant roles at leading companies such as Caterpillar, Autodesk, Collins Aerospace, and Hyster-Yale, where he developed a deep understanding of engineering processes and innovations.