The 3D Printing Revolution by Dr Sophie Parker

Digital dentistry is no longer a thing of the future but is a common component of modern dentistry. More and more clinicians are investing in 3D scanners and CBCT machines, while laboratories are turning to computer aided design (CAD) and 3D printing for manufacturing and prototyping.

The digital revolution has led to a boom in 3D printing sales and dentistry as an industry has no exemption from this. SmarTech Publishing recently announced its latest report on the 3D printing dental market, including an expected increase in market size to $9.5bn by 2027. SmarTech’s findings explain that the dental industry has grown by over 35% year-on-year in 2016 and 2017.

So what is 3D printing?
3D printing is the conversion of a digital model into a three-dimensional solid object. The model is manufactured layer by layer, a form of additive manufacturing. There are many types of 3D printing, however the most common forms used in dentistry are Fused Deposition Modeling (FDM), Polyjet, Stereolithography (SLA) and Digital Light Processing (DLP).

Types of 3D printing explained
SLA was the first 3D printing technique developed and patented in 1986. SLA is the polymerisation of a resin via a laser to create a 3D model. Similarly DLP uses the same technique of resin polymerisation using a light from a projector instead of a laser.

Align Technology has been using SLA manufacturing for Invisalign aligners since 1999 and dental laboratories today are adopting desktop SLA technology for the production of dental models, splints and appliances using certified dental resins. The resolution of SLA models is very high, however there are limited materials available and multicolour models are not possible.

FDM was invented in 1988 by Scott Crump, founder of leading 3D printing manufacturer Stratasys. FDM 3D printers build objects layer by layer from the bottom up by heating and extruding thermoplastic filament. FDM is already used in the dental industry for typodonts, drill guides, stents and the manufacture of dental devices.

The PolyJet process is different in that a carriage jets photopolymers onto the work space, which are then cured by a UV light. After a very thin layer is created, the process repeats itself by jetting additional layers until the part is fully formed.

Polyjet is capable of much higher resolution then FDM and the technology’s focus is on final product realism, smooth surfaces and fine feature detail. Resolutions of Polyjet 3D printing range from 0.032mm layer thickness down to 0.016mm and is comparable to SLA. Multiple materials can be printed at once including any combination of rigid, flexible, transparent or opaque materials and their composites. This makes Polyjet the favoured and obvious technology for Endo Reality Teeth.

The future of 3D printing in dentistry
Implants are now being produced by 3D metal printing, allowing a faster and more stream line manufacturing process of the surface texture with no post processing.

Combining scanning of the mouth, 3D modelling and 3D printing, dentists can produce their own in-house laboratory work, drill guides, stents and orthodontic devices.

3D printed models from CBCT data can allow difficult endodontics or zygoma surgery to be trialed by the clinician before treating the patient.

The possibilities are endless with digital data capture and CAD, the 3D printing revolution is now.