More than a manufacturing alternative - precisely fitting 3D-printed full dentures thanks to validated Ceramill workflow

What makes 3D printing of full dentures within the Ceramill System so unique?

The Denture 3D+ material from 3D Systems has been extensively validated by our Research and Development Department. This thorough examination has enabled us to greatly optimize both the design and the production process, so that reproducible and accurately fitting full dentures are guaranteed and can be fabricated by Ceramill customers in a most efficient manner (Fig. 1).

On the software side, validated and coordinated CAD parameters are essential for the 3D printing result. To this end for example, the Ceramill D-Flow software offers tooth pocket gap parameters adapted to the tooth concept (Ceramill FDS or Vigo) (Fig. 2).

On the production side, the special feature of the Ceramill workflow is a “for Ceramill” support and Buildstyle for the printing process, which we developed together with 3DSystems. These are adapted to the workflow of Amann Girrbach and also contribute to creating an excellent fit. The focus here was on the fit of the teeth and bases. In addition, during validation of the material in our department, the print or fit accuracy was found to be dependent on the material level or level of the 3D printer. To this effect, we have developed a Level Tool (available in the C3 portal) (Fig.3), with which the appropriate filling level for the respective printing job can be achieved.

In direct interaction with the “for Ceramill” Buildstyle, the Filling Level Tool creates precisely fitting results for the customer.

Automatic orientation and additional supporting structures are further features offered by the Ceramill workflow. What role do they play?

Both are important factors which influence an accurately fitting result. Even slight deviations in orientation can significantly influence the fit of full dentures. For this reason, orientation of the full dentures in the Ceramill workflow is selected such to ensure an optimal tooth and base fit on the model. This orientation is automatically transferred from the Ceramill software to the 3DSprint 3D printing software from 3DSystems, thus avoiding incorrect orientation. The placing of additional assistance structures (Fig. 4) serves as stabilization during the printing process and thus prevents distortion during the fabrication process with the NextDent5100 for Ceramill.

How difficult is the entry into the workflow for beginners?

To provide customers with a quick and easy introduction, detailed instructions are available, which explain all the steps involved in the final fabrication of the full denture. Additionally, there is a checklist which, in case of problems, points out possible sources of error and highlights the important steps for an accurately fitting result.