3D printed dentures: workflow, resins and what a lab needs to know

A 3D printed removable denture is made in a digital workflow: scanning, denture design in CAD software, separate printing of the base and teeth, washing, post-curing, bonding the teeth and finishing. For the lab, this means fewer manual steps, a reproducible result and a digital archive from which the denture can be printed again. The most important thing is to use a dedicated, validated resin for each stage – for example SHINING DENT DT02 or Graphy Tera Harz THD for the base – and to strictly follow the manufacturer's post-processing settings.

What the digital denture workflow looks like

The general sequence differs little, regardless of which manufacturer's system you use:

1. Data acquisition. The edentulous jaw is scanned with an intraoral scanner, or a poured model or impression is scanned in the lab. The bite registration and aesthetic information (midline, lip line, tooth length) are sent along with it.
2. Design. In the CAD software, the teeth are set up, the base is shaped and separate files are exported – the base with tooth sockets and the dental arch.
3. Try-in denture. In more complex cases, a try-in version is printed first and used in the clinic to check fit, occlusion and aesthetics.
4. Final printing. The base is printed in a gingiva-colored resin, the teeth in a tooth-colored resin.
5. Washing and curing. Uncured resin is removed, and the parts are post-cured in the specified mode.
6. Bonding the teeth, finishing and polishing.

In the Graphy THD description, the manufacturer summarizes the workflow as follows: 3D scanning → CAD → printing → washing / curing → finishing → fitting, and states that production time can be shortened from several days to the same day. How realistic this is in your lab depends on your order volume and whether a try-in stage is needed.

Which resins to use for the denture base

A denture base is a long-term appliance in constant contact with the mucosa, so the resin must be intended specifically for this indication. The IMMT range offers several options:

For try-in dentures, there is HeyGears Denture Try-in UV – an MMA-free resin used to check fit and occlusion before final production. It is not intended for the final denture. You will find a broader overview of the HeyGears line in the article HeyGears UltraPrint resins: which one to choose for models and dentures?

Resins for denture teeth

The teeth are printed separately in a tooth-colored resin. Here it is important to distinguish between long-term and temporary use:

• HeyGears Detax Freeprint Crown UV – the manufacturer specifies it for permanent crowns, bridges and denture teeth; a Class IIa medical device. According to Detax, Freeprint Crown teeth bond to a Denture Impact base without an additional intermediate step.
• HeyGears Tough Teeth For Try-in UV – a reinforced resin for complete and flexible denture teeth and temporary implant-supported dentures; according to the manufacturer, it is more fracture-resistant than standard try-in tooth resins and suitable for a longer provisional denture phase.
• SHINING DENT CB11 – a resin for temporary crowns, bridges and denture teeth, 7 shades (A1–B3).

Before setting up your workflow, check what duration a specific tooth resin is intended for according to its instructions for use, and do not carry a temporary resin over into a long-term appliance.

Printer, orientation and supports

Denture bases are large, bulky parts, so the build area and a stable process matter for the printer. SHINING DENT resins are used with SHINING 3D printers, such as the AccuFab-L4D / L4K with a 192 × 120 mm build area, while HeyGears and Detax resins are used with the HeyGears UltraCraft A2D-HD, which automatically recognizes the resin bottle and selects the parameters. You will find all models in the 3D printers section, and we discussed the criteria in a separate knowledge base article on choosing a printer for a lab.

The SHINING 3D denture base resin application guide recommends positioning the denture vertically or at an angle of 10–30°, not placing supports on the tooth sockets (fitting surfaces), adding supports in the border areas and not using too few supports – otherwise the print may fail. The general principle also applies to other systems: supports must not touch the mucosal surface or the tooth sockets, as their marks alter the fit.

Washing and post-curing

This stage determines not only surface quality but also the material's mechanical properties and biocompatibility. An insufficiently washed or under-cured base remains tacky and may contain residual monomers.

• SHINING 3D workflow. The application guide specifies washing in the FabWash station with isopropanol (≥ 75%) for the preset time, and with ≥ 90% isopropanol shortening the time by 1–2 min. Post-curing – FabCure 2, 10 min at 60 °C, after which the part is left to stabilize for 1–2 hours.
• HeyGears workflow. The UltraCraft Wash uses 99% isopropanol or 95% ethanol, and the UltraCraft AirCure selects the curing strategy based on the part type and material.
• Graphy workflow. The Tera Harz Cure N2 cures in a nitrogen atmosphere – according to the manufacturer, this eliminates the tacky surface layer and residual monomers.

The washing solvent, duration and curing mode for each resin are specified in its instructions for use – and those are what you should follow. More on this stage in the article Washing and curing 3D prints step by step.

Bonding the teeth to the base

This is the stage where mistakes most often occur. The SHINING 3D guide describes the following procedure: denture base resin is applied to the tooth sockets and along the margin line, the teeth are inserted without moving them, excess is wiped off before curing, and then it is cured from the labial and lingual sides, anteriorly and laterally – 30 s per side. During curing, the teeth and base must not be subjected to torsional force.

Practical tips:

• Use the bonding method specified by the base resin manufacturer, and do not mix different systems without the manufacturer's approval.
• The tooth sockets in the CAD software must have a sufficient but not excessive gap – too large a gap means a thick layer of adhesive.
• The dental arch is printed in one piece or with connectors – this makes accurate placement easier.
• Before bonding, check that the contact surfaces are clean and dry.

Finishing and polishing

Supports are removed at low speed, leaving a small margin, and the surface is then smoothed with coarse and fine grinding tools. The denture is then polished like a conventional denture – from coarser to finer polishing. The SHINING 3D guide also describes coating the labial surface with a mixture of base resin and GC GF71 for a higher gloss. Do not polish the mucosal (intaglio) surface – this alters the fit.

Characterization with gingival shades is possible, but use only staining materials compatible with the specific resin.

Limitations and what to avoid

• Not every resin is for a final denture. Try-in resins are intended for verification, not for wear.
• Open systems do not mean "any resin for any printer". A medical device must be manufactured with a validated combination of printer, resin and curing unit.
• Repairs and relines. Check whether the resin manufacturer allows the denture to be relined and repaired, and with which materials. For example, Detax Denture Impact is specified as compatible with Molloplast B and Mollosil plus.
• Milling is an alternative. Some technicians mill bases from Yucera PMMA Pink discs. More in the article PMMA discs: Mono, Multilayer or Pink.

Frequently asked questions

Can a 3D printed denture be definitive, or only temporary?

It can be definitive if the base and teeth are made from resins intended for long-term use (e.g. SHINING DENT DT02, Graphy THD, Detax Freeprint Denture Impact with Freeprint Crown teeth), and if the manufacturer's full post-processing protocol is followed.

Can the base and teeth be printed with a single resin?

The usual workflow uses two separate resins: a gingiva-colored one for the base and a tooth-colored one for the teeth. This gives both better aesthetics and more suitable mechanical properties for each part.

Which solvent should denture bases be washed in?

Most often isopropanol; some systems also allow ethanol. The concentration and duration are specified by the resin manufacturer – for SHINING 3D DT resin, for example, ≥ 75% isopropanol is specified.

Is a try-in denture necessary?

Not always, but in more complex cases (a new jaw relation, aesthetic requests) a try-in version made from Denture Try-in UV helps avoid remaking the final denture.

Can flexible partial dentures be printed?

Yes – Graphy Tera Harz TFDH and Detax Freeprint Denture Flex UV resins are designed for this, allowing flexible dentures to be printed instead of thermoformed.

Summary

3D printed dentures give the lab a reproducible workflow and a digital archive, but the result depends on choosing the right resins for the indication and on an exact washing, curing and bonding protocol. You will find all denture resins in the Resins section. Would you like to put together a printer, resin and post-processing package for your lab? Contact IMMT or call +370 601 00030.