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Dave Johnson Dental Lab, Inc. Wednesday, August 9th, 2023

Application guide: 3D Printing Custom Trays.

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Custom tray resin is a Class I biocompatible substance that can directly print custom impression trays for dentures, implants, crowns, and other complex cases. Utilizing specially designed impression trays that were digitally created guarantees reliable and accurate impressions and better patient outcomes. With less than an hour of labor required, this material can be used to print impression trays, increasing throughput while cutting labor costs. A physical or digital impression of the patient’s dentition is necessary for 3D printing custom trays . For the application of custom trays , the following items must be present: 

  • If a physical impression or model is required, use a desktop scanner.
  • Design software for the teeth
  • Low-speed dentistry handpiece with cutting and finishing wheels
  • Tools and materials for polishing are optional.
  • Isopropyl alcohol (IPA).

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Functions of a 3D-printed custom tray

Scan

Dental design software needs a digital impression of the patient’s anatomy in order to create a custom tray or 3d printing dental model. This information can be obtained by using a desktop 3D scanner to scan a physical impression or poured model or by using a 3D intraoral scanner to scan the patient directly.

Design

  • Digitally create the custom tray dentalusing one of the many dental software programs available. Another option is to send a digital impression to a dental CAD service provider, who will use it to create the design.
  • Export the STL file to start manufacturing after the case has been precisely designed. Most dental design programs produce an STL manufacturing file. Find the file and import it into the print-ready program.

 Print

  • Import File(s): After finding the design files on your computer or network, drag them into the program or select them from the File menu to open them.
  • Material selection: Selecting a material is done by clicking the printer box in the job info menu on the right. From the material dropdown menu, pick Custom Tray.
  • Orientation: Whenever possible, keep the intaglio surface away from the build plate. Click on a tray, then drag the sphere to rotate it. Depending on the number of parts to be printed, trays can be attached to the build plate either nearly vertically or almost horizontally.
  • Generate supports: Select Auto Generate Selected or Auto Generate All from the left-hand menu to generate supports.
  • Manual support editing: If, after automatic generation, a support point is not in the ideal location, it may be moved by selecting Edit from the support menu.
  • Sending the job to the printer: To send the job to the 3D dental printer, click the orange printer icon on the left. A print dialog box with a printer selection option will now show up. Click the Upload Job button to start sending the job to the printer.
  • Set up the printer: Shake the Tray Resin cartridge before inserting it into the Form 2 or Form 3B printer along with a build platform and an appropriate resin tank.

 Post-processing

Always wear gloves when working with parts and uncured resins. Scraping or part removal tools should be inserted beneath the part raft and rotated to remove printed parts from the build platform.

Washing 

  • It is best to wash the custom tray dental printed part with solvent in a well-ventilated area while wearing the proper safety goggles and gloves.
  • 10 minutes in an isopropyl alcohol-filled Form Wash will clean the printed parts.
  • Make sure the parts are completely submerged in IPS when washing.
  • Long-term effects on the performance and dimensional accuracy of printed parts could result from excessive wash times.

 Drying: After removing the components from the IPA, leave them at room temperature to air dry for at least 30 minutes. Check the cleanliness and dryness of the printed parts. Place the dried printed parts in the post-cure at 60°C for 30 minutes.

 Support removal: To remove supports, use a cutting disk, handpiece, or other part removal tool. Look at the specialized tray. Discard the part and print a new one if any cracks are discovered.

 Finishing and polishing: If any rough marks remain on the surface of the 3D printed tray after the support has been removed, smooth them down with a wheel or carbide rotary and handpiece to improve patient comfort.

 Cleaning and sanitizing

  • Parts cleaning: Completely post-processed parts can be cleaned with a specialized soft toothbrush, neutral soap, and room-temperature water.
  • Disinfection: The finished custom tray may be cleaned and infected in accordance with facility protocols. To ensure the integrity of the impression tray, check the component for cracks after disinfection.

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