Article Presented By: Todd Fong, CDT
Throughout my extensive career as a Master Ceramist, I’ve become a big proponent of the integration of 3D printing technology for the printing of dental appliances. When executed properly, this innovative technology not only saves significant time and money, it yields appliances that rival the fit and appearance of conventionally manufactured ones. Discussions on various online forums, however, have highlighted a disconnect among my peers regarding the adoption of 3D printing in dentistry. As I’ve talked to fellow Technicians about their experiences, it’s become evident that their hesitance largely stems from inconsistent outcomes that are due to a lack of knowledge about the washing and curing phases. It’s apparent that many dental offices and labs lack an understanding of the criticality of employing a validated system for printing, washing, and curing. These steps are pivotal for ensuring the success of the final product, particularly given the ever-evolving array of available resins.
Background
Not all resins are alike; they require tailored washing and curing processes. Just as a cotton shirt, wool sweater, and leather jacket wouldn’t be laundered and dried in the same manner, different resins require different washing and curing processes. Similarly, various 3D dental appliances – models, surgical guides, provisional crowns, full dentures, and all-on-x temporary prosthetics – demand distinct resins and corresponding washing and curing parameters. Failure to adhere to the proper settings can result in issues like shrinkage, color instability, or compromised structural integrity.
If not adequately cleaned, excess resin residue invariably leads to subpar outcomes and extremely poisonous toxic monomers in their uncured state. Likewise, improper curing – whether under- or over-cured – can jeopardize the clinical efficacy of the appliance and cause possible harm to the patient. For these reasons, employing appropriate validated washing and curing units, calibrated to the resin’s manufacturer’s requirements, is paramount.
Common Problems with Washing and Curing
Several common errors can plague the washing and curing process for 3D-printed appliances:
- Failure to validate the 3D printing resin for compatibility with both washing and curing units, as well as the printer itself, often results in incomplete washing and curing.
- Neglecting to use an isopropyl alcohol (IPA) bath correctly for washing certain Class 1 and Class 2 resins, risks inadequate cleaning and potential cross-contamination of the appliance.
- Discrepancies in light intensity between the printer and curing unit can yield suboptimal outcomes. Additionally, a lack of capability to extract toxic uncured resin during the washing process can compromise the final accuracy and fit of the appliance and create potential health risks to patients.
- Some curing units lack a pressurized vacuum/nitrogen chamber to address the oxygen-inhibited layer, further hindering the curing process.
This Is NOT To Say That Any 3D Printer Will Suffice
Even with optimal washing and curing units, the choice of a 3D printer remains crucial. Personal experience has revealed significant discrepancies in the final product quality when comparing different printers. This underscores the importance of selecting a printer that aligns with the desired outcome in terms of aesthetics, precision, and fit.
A Solution
The DentaMile 3D printing system offered by DMG comprising the 3Demax printer, 3Dewash washing unit, and 3Decure curing unit has proven highly effective. DMG’s stringent validation process ensures compatibility with various resins, including those from other manufacturers, guaranteeing optimal curing results. Additionally, these units are designed to mitigate common issues encountered during the washing and curing phases. Features such as specific manufacturer settings, matched light intensity, and a pressurized vacuum chamber for curing oxygen-inhibited layers enhance the overall efficacy of the process.
Summary
The 3D printing process presents numerous advantages for dental labs, practices, and patients alike. However, to fully capitalize on these benefits, it’s imperative to recognize that the process extends beyond just printing. Proper validated washing and curing are very integral steps that significantly influence the final outcome. By embracing validated systems and employing best practices throughout the entire process, practitioners can optimize results and elevate the standard of care in dental appliance fabrication.
About the Author
Todd Fong is a Master Ceramist and Certified Dental Technician at Dr. Diana Fat D.D.S. Prosthodontics in Sacramento, CA . He graduated from Diablo Valley College Dental Technicians program in 1983 and has owned and operated a high-end boutique dental lab from 1987 through 2010. He completed Post Graduate studies at UOP Dental School San Francisco and Las Vegas Institute for Advanced Dental Studies. Throughout his career, he’s traveled around the country to lecture and lead hands-on learning workshops as a Key Opinion Leader for many dental manufacturers.