Provided by the Dentist

• A final functional impression of the mucous tissue of the jaws. 

• A bite rim with all necessary information, such as: lip line, midline, canine position, and occlusal plane.

• Prescription with desired tooth shape, shade, and other clinical considerations.

Made by Formlabs

Made by Third Parties

• ​​​​​Desktop scanner

• A dental handpiece and tools for acrylics

• Handheld UV light cure unit (must be between 365nm - 405nm)

• Optional: 

  • Lathe for polishing

  • Steam cleaner

  • Ultrasonic bath

  • Silicone tongs

  • Pumice and polishing compound

  • Third-party bond kit

  • Sandblast media

Made by Formlabs 

• Latest PreForm Dental software and printer firmware

Made by Third Parties 

• Denture design software

This may include:

Digital denture design software requires a digitized model or an intraoral scan of the patient’s oral anatomy in order to design the removable prosthetic.

The best available method for creating a digital file for edentulous patients is to scan the fully articulated, poured, or printed model and wax rim with a desktop laboratory scanner.

To optimize the accuracy of the bite, use a desktop scanner that can scan the bite of the fully articulated model without unmounting it.

Adjust your workflow according to the software you use. 

Install the material libraries provided by Formlabs:

> Download our 3Shape materials library (DME).

> Install the exocad materials library using exocad dentalshare.

 Use the following tips while designing the denture. 

General design recommendations: 

• Base thickness: > 2.0 mm (add a 0.1–0.2 mm buffer for polishing). A thicker base ensures a stronger 3D printed denture.

• Retention elements requiring high deflection during seating (such as traditional C-clasps) may lead to premature fracture and should not be printed with Denture Base Resin V2.

• It’s recommended to disable drill compensation, as it isn’t relevant for 3D printing and can negatively affect the fit of the denture base.

• Formlabs libraries include a predefined coupling setting. If you’re using software other than exocad or 3Shape, set the offset between the base and teeth to 0.1 mm or less to ensure a proper gluing gap.

• Denture Base Resin V2 is more translucent than traditional acrylics, so it’s best to use tooth libraries without roots, with only short root portions, or trim the root in CAD if the software allows. This helps maintain a natural-looking result.

Denture teeth or CAD libraries are an important part of the digital denture process. Library compatibility varies by software. For example, some open libraries restrict output, while other libraries generate the denture teeth splinted, but not individually.

3Shape

> Open the Download Center in the 3Shape Dental Manager Control Panel to download new libraries. See 3Shape’s documentation for details.

Exocad

> Install teeth libraries following the instructions for exocad dentalshare.

Once you export the STL files from the denture design software, import the files into PreForm Dental to prepare them for printing. You may need to manually set up your files in the PreForm Dental Workspace. To select the Dental Workspace, go to the View dropdown menu and select Choose Workspace.  

Select the material for printing: Premium Teeth or Denture Base V2.

Orientation:

Users may print at any angle, but fit may be suboptimal at angles steeper than 70 degrees.  An angle of 60 degrees is recommended since it results in excellent part accuracy while still being very space-efficient with the build platform area. The anterior buccal part can face towards or away from the build platform. We recommend placing the supports on the intaglio face of the denture base.

To generate supports automatically, under the Supports menu, ensure Auto-Placement is selected and click Auto-Generate All.

If any supports appear in undesired areas — especially if they interfere with anatomical features or increase post-processing complexity, return to the Supports menu and select Manual Placement to modify supports. Toggle the view to “Show touchpoints only” for better visibility.  Clicking directly on an existing touchpoint will remove it.

PreForm will alert you if you have an undersupported model and need to add additional supports for a successful print. 

Orientation:

Position the tooth arch at approximately a 0-30° angle to the build platform. The occlusal surface of the teeth can face towards or away from the build platform, depending on preference in finishing the part.

Supports:

To generate supports automatically, under the Support menu, ensure Auto-Placement is selected and click Auto Generate. If any supports appear in undesired areas — especially if they interfere with anatomical features or increase post-processing complexity, return to the Supports menu and select Manual Placement to modify supports.

Thoroughly shake the resin cartridge before use. Prepare the 3D printer by inserting a resin tank, resin cartridge, and build platform into the printer. Send the job to the printer from PreForm, and start the print.

See the instructions for post-processing in our Instructions for Use for Premium Teeth Resin and Denture Base Resin V2.

Parts may be removed from the build platform prior to washing or alternatively parts may be washed directly on the build platform in the Form Wash, whichever best suits your workflow. 

To remove uncured or excess resin, refer to the instructions in the IFU or Manufacturing Guide.

Washing times for Formlabs resins can be conveniently found on this page.

If parts do not appear clean after washing, use a soft-bristle brush and Isopropyl Alcohol in a squirt bottle to clear the denture of residue and replace solvent in wash.   

Do not let parts sit in Isopropyl Alcohol for longer than needed.

Parts may be washed with or without supports, but washing without supports will allow for optimal resin removal. If parts are processed with supports, it is important to ensure all resin residue is removed from the part. 

After washing, allow the parts to air dry for 30 min, or use compressed air to remove alcohol from the parts’ surfaces and air dry. 

Once the parts have been washed and dried, remove the raft and supports from the base and teeth. To save time, consider using a low-speed dental handpiece, cutting disc, and a universal silicone polisher wheel.

Please note that there are several potential workflows depending on your material choices and preferred method of assembly. Please refer to the Manufacturing Guide for full instructions.

Ensure parts are completely dry and free of IPA. 

Insert the teeth into the denture base to test the fit. If anything inhibits seating, trim the teeth and the base as needed using a hand tool. 

Once your tooth arch fits without obstructions in the sockets on the printed base, the two parts can be assembled. Prepare the denture base by applying, in each pocket, a small amount of liquid Denture Base Resin V2 to the uncured denture.

Affix uncured teeth printed in Premium Teeth Resin to the base.  Remove any excess liquid resin with a brush and/or a lint-free cloth.

Tack cure interproximal spaces between each tooth with a handheld UV light for 5-10 seconds each or as necessary. All in-house testing at Formlabs was done with a 405 nm handheld UV light, but any light source between 365 nm and 405 nm may also be used.

Place the printed parts occlusal side up in a Formlabs post-curing unit, select Denture Base V2, and cure for the required time. For the Form Cure V2 or Cure L V2, there is a 15-minute, 80 °C preheat followed by a 5-minute, 80 °C cure. Full curing instructions can be found in the Manufacturing Guide.

Allow the cure unit to cool down to room temperature between cure cycles.

Ensure denture base parts are completely dry and free of IPA. 

Place in a Formlabs post-curing unit, select Denture Base V2, and cure for the required time. For the Form Cure V2 or Cure L V2, there is a 15-minute, 80 °C preheat followed by a 5-minute, 80 °C cure. Full curing instructions can be found in the Manufacturing Guide.

Allow the cure unit to cool down to room temperature between cure cycles.

Ensure Premium Teeth parts are completely dry and free of IPA.  

Place in a Formlabs-validated post-curing unit, select Premium Teeth, and cure for the required time. In the Form Cure V2 or Cure L V2, there is a cure time of 5 minutes at 80 °C. Full curing instructions can be found in the Manufacturing Guide for Premium Teeth Resin. 

Allow the cure unit to cool down to room temperature between cure cycles.

Follow the manufacturer’s instructions.

Once all parts are fully cured and cool, insert the teeth into the denture base to test the fit. If anything inhibits seating, trim the teeth and the base as needed using a hand tool. 

Once your tooth arch fits without obstructions in the sockets on the printed base, the two parts can be assembled. 

To securely attach the denture base to the teeth, we recommend using a dental-grade, self-polymerizing, gap-filling bonder for optimal results. While Formlabs has tested the Ivoclar Ivotion Bond Kit, any similar product designed for bonding acrylic to composite materials will be effective. Self-curing bonding systems are preferred over UV-curing options to prevent additional UV light exposure to the printed parts. To ensure proper bonding, roughen the bond surfaces (both denture base and teeth) with sandblasting or a carbide bur. Please follow the manufacturers’ instructions for use.

Once assembled, 3D printed dentures can be pre-polished and polished using traditional methods. For optimal efficiency, if available, we suggest utilizing a lathe with medium-fine pumice and a high-gloss acrylic polishing compound. While traditional polishing offers the best finish, a dental-grade light-curing varnish, such as Kulzer Palaseal© or GC Optiglaze©, can be used as an alternative.

After confirming the desired outcome, cleanse the denture using mild soap and water and rinse thoroughly. A soft-bristled brush or ultrasonic bath may be used if desired. Your denture is then ready for delivery.

Congratulations! You have successfully created a beautiful and natural-looking denture for your patient.

Dentures produced with Formlabs resins are fully repairable and relinable. Full instructions can be found in the Manufacturing Guide..

Ensure the part is disinfected and dry before beginning the repair.

Physically etch the entire repair surface with a carbide bur and/or sandblasting media.  A third-party universal/multipurpose primer may be used to aid in bonding. Follow the manufacturer’s instructions.  

Apply Denture Base Resin V2 to the repair area with a brush, allowing the material to flow to avoid bubbles. Tack cure with a handheld UV light to secure the repair. All in-house testing at Formlabs was done with a 405 nm handheld UV light, but any light source between 365 nm and 405 nm may also be used. 

If needed, add additional Denture Base Resin V2 and tack cure using a handheld UV light, repeating until desired thickness is reached. It is beneficial to overbuild the repair area as material will be removed during finishing and polishing.

Place in a Formlabs post-curing unit, select Denture Base V2, and cure for the required time. For the Form Cure V2 or Cure L V2, there is a 15-minute, 80 °C preheat followed by a 5-minute, 80 °C cure. Full curing instructions can be found in the Manufacturing Guide.

Allow the cure unit to cool down to room temperature between cure cycles.

Finish and polish the repair area to remove any surface residue and ensure patient comfort. Follow the instructions above in Section 7.

Ensure the part is disinfected and dry before beginning the repair.  

Tack the fractured denture together with sticky wax or glue. 

Fabricate a putty model using an appropriate dental stone or plaster. 

After the denture is removed from the model, wax may be removed with mild steam cleaning or warm (not hot) soap and water.

Prepare the fracture for repair by physically etching the repair surface with a carbide bur and/or sandblasting media.  It is important to ensure that there is adequate surface area for the repair material to make a strong bond to the appliance. A third-party universal/multipurpose primer may be used to aid in bonding. Follow the manufacturer’s instructions.  

Prior to returning the prepared denture parts to the model, a 3rd party release agent may be applied to the putty model used to aid in the removal of the denture following repair.  Secure denture onto the putty model with sticky wax, being sure to keep the repair area free from wax or other contamination. Apply Denture Base Resin V2 to the repair area with a brush, allowing the material to flow to avoid bubbles. Tack cure to secure the repair. 

If needed, add additional Denture Base Resin V2 and tack cure using a handheld UV light, repeating until desired thickness is reached. It is beneficial to overbuild the repair area as material will be removed during finishing and polishing.

Manually remove any excess sticky wax, if needed. Place in a Formlabs post-curing unit, select Denture Base V2, and cure for the required time. For the Form Cure V2 or Cure L V2, there is a 15-minute, 80 °C preheat followed by a 5-minute, 80 °C cure. Full curing instructions can be found in the Manufacturing Guide.

Allow the cure unit to cool down to room temperature between cure cycles.

Finish and polish the repair area to remove any surface residue and ensure patient comfort. Follow the instructions above in Section 7.

Ensure the part is disinfected and dry before beginning the repair.  

If any tooth material remains in the tooth socket, remove by grinding with a bur. 

Prepare the denture to receive the replacement tooth/teeth by physically etching the repair surface on the denture base with a carbide bur and/or sandblasting media. 

Use sticky wax, if desired, to position the new tooth/teeth. Wax may be removed with mild steam cleaning or warm (not hot) soap and water.

Due to the potential for tooth discoloration with repeated UV light exposure, we recommend using a dental-grade, self-polymerizing, gap-filling bonder for optimal results. While Formlabs has tested the Ivoclar Ivotion Bond Kit, any similar product designed for bonding acrylic to composite materials will be effective. Please follow the manufacturer’s instructions for use to attach new tooth/teeth to denture base.

Finish and polish the repair area to remove any surface residue and ensure patient comfort. Follow the instructions above in Section 7.

Hard and soft reliners that are compatible with acrylic/resin may be used with Denture Base Resin V2.

Prepare the surface for relining.  For maximum bond strength of the reliner to the denture base, it is very important to thoroughly roughen the part surface completely up to the edges using a coarse carbide bur.

The use of a “universal” or “multipurpose” primer may be used to aid in bonding. Refer to the manufacturer’s instructions for use.

Formlabs has tested the following relining materials: 

• GC Reline Chairside Hard Denture Liner

• GC Reline II Soft

While Formlabs has tested the above relining materials, any similar product designed for bonding to acrylic/resin materials will be effective. Please follow the Manufacturer’s Instructions for Use.