Announcing New Denture Base Resin for Lifelike Dentures That Deliver Long-Term Performance

Introducing the new Denture Base Resin V2, a high-impact, long-term biocompatible material for producing strong, lifelike dentures that exceed ISO 20795-1 standards. The new formulation is tougher, with more lifelike aesthetics and substantially faster processing times, for less labor and a low cost per part. With the release of this updated formulation, dental professionals can print full dentures on Formlabs Form 4B and Form 4BL 3D printers using a streamlined, validated process.

Available in three semi-translucent pink shades, new Denture Base Resin empowers denturists and technicians to deliver tough, lifelike dentures with confidence. 

Available in three semi-translucent pink shades – Original, Light, and Dark Pink – the material's optimized translucency blends naturally with patient tissue for gingiva that looks and feels authentic. Users accustomed to Lucitone Digital Print will find the aesthetics familiar.

Deliver dentures with the impact-resistance to withstand everyday wear and accidental drops. New Denture Base Resin is strong enough to withstand mastication. With a fracture toughness of 2.43 MPa.m1/2 and a work of fracture of 1,000 J/m2, the material is considered high-impact, making it resistant to crack propagation from accidental drops. The improved mechanical properties enable technicians and denturists to deliver dentures with long-term performance. 

Denture Base Resin has the compatibility to be relined with a range of hard and soft materials and repaired using standard repair methods, giving dentists and lab technicians the confidence to guarantee their work for years of patient wear.

Formlabs Denture Base Resin is comparable to Lucitone Digital Print 3D Denture Base, with flexural and toughness properties that exceed ISO 20795-1 standards and a translucency of ~35%, for more realistic aesthetics than traditional denture bases.

Dentsply has published settings for printing Lucitone 3D Denture Base on Form 4B by using Open Material Mode (OMM). However, printing with Lucitone 3D Denture Base Resin requires manually pouring the resin into the resin tank. By contrast, Denture Base Resin comes in a Formlabs cartridge, for automatic resin dispensing on Form 4B and Form 4BL, and at a lower price point. Additionally, Denture Base Resin V2 is the only denture base material with print settings available for large-format Form 4BL 3D printers.

Labor is the most costly part of denture production. By 3D printing denture bases, technicians and denturists can save half an hour to an hour and a half of work per denture, while fully digital denture workflows save almost 60% over traditional workflows. Even 3D printing the denture base and using stock teeth can save almost 50% over pouring or milling bases.

Reach the final denture in fewer steps without additional equipment. Denture Base Resin comes in a Formlabs auto-dispense cartridge, for no-mess printing, and is fully validated on the Form 4B/BL Ecosystem.

It takes 2 h 30 min to print six denture bases on Form 4B (or 1 h 47 min to print just one), followed by a 10-minute IPA wash, and 30 minutes of air drying. 

At this point, dentures can be assembled in 10-20 minutes using Denture Base Resin as a bonding agent if using printed Premium Teeth Resin denture teeth. Once assembled, dentures are post-cured in Form Cure for 20-minutes.  Previous versions of this resin required a three-hour post-cure process involving submerging the part in preheated glycerol. The new Denture Base Resin has a 9x faster cure time with fewer steps. Once post-cured, finishing and polishing take 10 minutes, for a total time of less than four hours to print and assemble.

Denture bases printed with Denture Base Resin V2 offer flexibility and are compatible with teeth printed with Formlabs Premium Teeth Resin, milled teeth, stock or carded teeth, or other 3D printed teeth. To assemble dentures with Premium Teeth Resin, liquid resin can be used as a binder. For other teeth, third-party binders such as Ivoclar Ivotion Bond Kit can be used.

Download the Instructions for Use for the complete manufacturing guide.

A denturist for over 30 years, Rob Bredewoud of Dental Design Vof has stayed on the cutting edge of dental innovations, testing hardware and materials from a range of manufacturers and teaching workshops on digital dentistry. When it came time to release a new Denture Base Resin, Formlabs Dental had Bredewoud do some tests.

Bredewoud’s business is fully digital, delivering 150-200 cases a year to patients in the Netherlands. He finds that Denture Base Resin V2 has similar aesthetics to Lucitone 3D Denture Base, and appreciates the ~35% translucency. Additionally, he finds that grinding bases printed with Denture Base Resin feels good — like working with PMMA — and there’s no chipping during the process.

New Denture Base Resin offers lifelike aesthetics and long-term biocompatible performance — all at a lower cost per part than competitors. Streamlined workflows with the Form 4B/BL Ecosystem minimize labor, mess, and time to delivery. Plus, impact resistance and broad support for hard and soft relining materials mean denturists and technicians can confidently guarantee their work for years of patient wear.

Buy new Denture Base Resin to start printing dentures on your Form 4B or Form 4BL, or contact a reseller to learn more.