Formlabs Dental and Digital Smile Design (DSD) have joined forces to redefine what’s possible in modern dentistry. Since 2019, this collaboration has brought together DSD’s pioneering vision in comprehensive guided dentistry and Formlabs Dental’s leadership in advanced dental 3D printing technologies. By combining clinical innovation with cutting-edge manufacturing tools, we've been working to develop the next generation of digital workflows and practical solutions for dental professionals.

As part of this joint effort, we’ve explored and tested a variety of protocols to create the best-in-class mock-ups, essential tools for diagnostic, clinical, and communication purposes. DSD has continuously pushed the boundaries of what 3D printing can offer in the dental space, providing invaluable feedback that has shaped product development and inspired new clinical applications. Meanwhile, Formlabs Dental has delivered the materials, hardware, and reliability to turn these ideas into tangible, everyday solutions.

Together, we have witnessed the significant evolution of the mock-up technique. What once began with printing physical models to create PVS indexes has now advanced to the direct printing of biocompatible, end-use appliances. Today, 3D printing offers incredibly flexible approaches, streamlining workflows and enhancing patient outcomes.

This guide presents three proven protocols for using 3D printing to fabricate mock-ups, offering flexible, efficient, and innovative options to suit a wide range of clinical needs. Below, we explain: 

• How to choose the best 3D printing workflow depending on the type of mock-up you need to produce

• Provide guidance on selecting the right approach

• Walk you through the full 3D printing process from design to final outcome

This comprehensive guide is the result of many years of collaborative work. It has been prepared after multiple intensive sessions, extensive testing, and valuable insights gained from practical application, including during DSD Clinical Courses. The authors, Dr. Luken de Arbeloa and Dr. Elisa Praderi, have dedicated years to bringing these concepts together into this consolidated resource.

The mock-up has long been a cornerstone of restorative and esthetic dentistry, a trusted tool to help patients visualize potential outcomes. In recent years, DSD has redefined its role. By integrating psychology, 3D design, and structured clinical workflows, DSD transformed the mock-up into a powerful bridge between patient motivation and clinical execution. No longer just a visual aid, the mock-up is now a communication tool, a motivational driver, and a technical reference — all depending on the timing and intent within the treatment journey.

At the core of the DSD approach is the understanding that mock-ups serve two very different purposes: motivation and technical execution. These are separated by a key clinical moment: case acceptance.

If we look at the DSD Workflow, the listed steps are followed:

Based on the above, we can identify that we would use different types of mock-ups for different phases and purposes.

Since this mock-up is used primarily for photos or social-distance visualization, ultra-high precision isn’t required — layer heights of 100 to 200 μm are more than adequate. This makes it ideal for fast prints using cost-effective materials. For example, we can print a model in 160 or 200 μm layer height with Form 4B in less than 10 mins. 

Another alternative that has appeared most recently is the use of biocompatible tooth-colored resins for the production of ‘the shell’. For example, we can print the motivational mock-up using Premium Teeth Resin at 100 μm that will take 20 minutes. This process becomes more efficient as there are less steps involved and less material consumption.

The workflow may include direct printed shells or detailed mock-ups transferred using printed indexes. Precision is critical at this stage, requiring high-resolution 3D printing and careful material selection to ensure reliable handling and fit. Ultimately, the technical mock-up validates and guides the clinical protocol, helping dental professionals execute complex restorative procedures with confidence, consistency and predictability.

The following table summarizes the concepts of the different types of mock-ups:

The DSD team has already prepared valuable guides that offer a thorough analysis of the mock-up's concept and the evolution of the technique. For more detailed information, you can refer to “The Complete Guide to the DSD Mockup Success Formula.”

From a 3D printing perspective, each method has a specific recommended material and approach. Motivational mock-ups require less precision (layer heights of 100–200 μm are sufficient), while technical mock-ups demand maximum accuracy and material fidelity (50 μm).

By understanding the purpose behind each type of mock-up and applying the right 3D printing strategy, dental professionals can elevate both patient engagement and clinical outcomes, combining emotion and precision like never before.

In the full digital workflow utilizing 3D printing, the following steps are covered:

In addition to connecting the motivational and technical mock-ups to the right 3D printing materials and strategies, there are other questions that dental professionals need to ask themselves to confirm they are in the right position to adopt each workflow.

The first option is to print the wax-up model, which professionals can then use to fabricate the PVS index.

Tools needed to do this protocol:

Protocol 1: Model Production used to fabricate a PVS Index

Workflow Steps

• The wax-up will be done on the imported data that was acquired in the first appointment with the intraoral scanner and digital pictures and videos.

• For the motivational mock-up, the wax-up design should be only additive and designed mainly in the buccal area.

• For the technical mock-up, the wax-up is done following the traditional principles, looking for proper function and performance.

• There are different softwares available that you can use to do the digital wax-ups such as 3shape, exocad, NemoTec, among others.

When analyzing the 3D printing workflow, one of the important steps is selecting which model resin to use.

There are different model materials available from Formlabs Dental which can fulfill this application including Fast Model Resin, Grey Resin V5, and Precision Model Resin. In order to select the right material, it’s important to analyze the requirements for each application.

• For motivational mock-ups, we need a fast solution as the objective is printing a model with the wax-up that doesn’t need to be the most precise option. Based on this criteria, the best option is to use Fast Model Resin. This material enables the printing of models in 100, 160, and 200 μm layer height settings. Any of these layer height options work for motivational mock-ups. It’s up to the dental professional to define the layer height based on their personal preferences.

• For technical mock-ups, we need a solution that provides a smooth surface finish and precision so we can accurately transfer the planned design to the patient’s mouth. In this case, Precision Model Resin printed at a 50 μm layer height setting would offer the best surface accuracy. The PVS indexes produced upon these models will accurately transfer the anatomical features and textures designed.

Though there are other materials available such as Grey Resin V5 and White Resin V5, these are less versatile for other dental applications. Additionally, neither offers the speed of Fast Model Resin nor the precision of Precision Model Resin.

The following table summarizes the main differentiating points between Fast Model Resin and Precision Model Resin.

When preparing the models to print, there are a number of considerations including the type of model being printed, print orientation, and layer height.

3.1 Model Type

The design of a model, including whether it is solid, hollow, or honeycomb, impacts its print orientation and the minimum wall thickness required for successful printing. For hollow or honeycomb models, it may be necessary to add drain holes to the base design. This helps to minimize the suction cup effect that can occur when printing these types of models directly on the build platform. The following table compares the advantages and disadvantages of printing each model.

3.2 Print Orientation

Print orientation is one of the variables that affects print time, the number of models that can fit in one build, and the direction the layers are built. When printing models, there are two possible options: 

• Printing the models flat against the build platform with their base directly on the build platform surface.

• Printing models vertically or angled with support structures. 

Each option offers different advantages and disadvantages, which are summarized below.

3.3 Layer Height 

Fast Model Resin and Precision Model Resin offer different layer height options, as illustrated in the comparative table. Clinicians can select the material based on the mock-up type, desired print time, or cost per part, while also considering the optimal layer height. It's important to remember that layer height directly influences print time and surface finish. The table below provides a summary of these concepts.

Following material selection and nesting in PreForm Dental, the parts are printed and post-processed. The 3D printing workflow involves several steps: printer setup, washing, drying, and post-curing. The total production time, including these final steps, varies per material used.

4.1 Setting up Form 4B

When printing with the Form 4B 3D printer, the following are required: a resin tank, resin mixer, build platform, and resin cartridge of the selected material. Once these are correctly inserted the print job can be sent from PreForm Dental to the printer.

4.2 Post-processing

The silicone (PVS) index can be created directly on the printed model. There is no need to apply any separating agent to the model. It’s important to bear in mind the thicknesses of the PVS material in each section. Also, the cuts of the index need to be properly done as shown in the following sequence.

Once the index is created, it will be used to do the mock-up in the patient’s mouth. The full clinical procedure can be seen in the "The Complete Guide to the DSD Mockup Success Formula".

Another 3D printing option that works for both motivational and technical mock-ups is to print the index with a biocompatible resin to transfer the designed wax-up to do the mock-up in the patient’s mouth.

Tools needed to do this protocol:

Protocol 2: Printed Index With IBT Flex Resin

Workflow steps

In this case, follow similar steps to those in protocol one during the design phase. Do the wax-up on the intraoral data that was captured from the patient. After the wax-up is done, the design of the index can be done upon it. Important parameters to bear in mind while doing the design of the digital index:

• Minimum thickness: The walls of the index need to be 4-5 mm thick.

• Limits: Adjust the design to fit perfectly in the cervical area.

• Undercuts and interproximal areas: Observe the undercuts you have and need. This technique enables replicating undercuts in a very reliable way.

• Offset from teeth: This needs to be zero.

• Flat plane: The part of the index that will be facing toward occlusal needs to be designed with a flat surface so it can be printed directly to the build platform.

• Extension: For motivational mock-ups, design a full-arch index. Define the palatal cut in a precise way to facilitate the cleaning process (removal of excesses of the bis-acryl resin).

When designing one of the planes of the tray to be flat, the parts shall be placed with this surface directly on the build platform. This will provide the fastest print speed as the model is self-supported.

Following nesting in PreForm Dental, the parts are printed and post-processed. The 3D printing workflow involves several steps: printer setup, printing, washing, drying, and post-curing. Total production time varies depending on the layer height chosen for printing.

4.1 Setting up Form 4B

Insert a build platform, resin tank, resin mixer, and IBT Flex Resin cartridge in the printer. Once the printer is set up, send the print job from PreForm Dental to the printer.

4.2 Post-processing 

Post-processing of parts printed with biocompatible resins requires following the steps established in the Manufacturing Guide.

Wash:

• After parts are removed from the build platform, they need to be washed in IPA (99%) in the Form Wash (2nd Generation) at High Speed in two steps (20 min + 10 min). It’s important to use a dedicated Form Wash for washing parts printed with IBT Flex Resin (the wash should not be used for parts printed in other materials) and follow the exact timing as presented in the Manufacturing Guide.

• Immediately after washing, it’s important to dry the printed parts with compressed air to ensure that there is no remaining IPA or resin on the printed part, especially in the intaglio surface. This is critical to ensure proper fit of the appliance during the clinical execution. The following picture shows how an insufficient wash can alter the intaglio surface.

• Allow parts to dry for at least 30 minutes before proceeding to post-curing.

Cure: Parts need to be finally cured in the Form Cure (1st Generation) or Form Cure (2nd Generation) for the time and at the temperature in the IBT Flex Resin Manufacturing Guide. This final step will ensure parts are ready to be used. The following graphics summarize the overall process and production time.

In this case, the index is going to be used just like a traditional PVS index with bis-acryl resin. No separating agent is required when using bis-acryl resin with the printed index. However, users should always confirm extraorally that their chosen bis-acryl material does not bond to the printed parts before intraoral application.

In the digital workflow, we have full control over the thickness of the material, allowing us to create precise, efficient designs in just 15–20 minutes. This not only improves accuracy but also leads to better clinical results with minimal excess. One key advantage is the precision in the palatal area, making it easier to clean and manage during placement. Excess material can easily be removed from both the buccal and palatal surfaces, so when the guide is removed, the mock-up is already clean and complete. For optimal flexibility and handling, the buccal area should maintain a thickness of around 4.5 mm. With this approach, we can produce a printed guide that is both flexible and accurate, perfectly replicating what we used to achieve with a traditional silicone (PVS) index. The major difference lies in control: digitally, we can fine-tune the buccal thickness and make virtual cuts in the occlusal and palatal areas, resulting in easier clean-up and more efficient use of material.

An alternative to create the mock-up that utilizes 3D printing is to print the shell directly with a tooth-colored resin. The development of biocompatible resins enables this technique and speeds up the process. 

Tools needed to do this protocol:

Protocol 3: Printed Mock-up Shell with Tooth-Colored Resins

Workflow Steps

In this case, we are focusing on producing the shell for the motivational mock-up. The shell is only an additive design. The process begins with a design split into three separate STL files, representing distinct sections of the arch (anterior, and two posteriors). Why three? Traditional full-arch shells (like in the early DSD workflows) often cracked or failed upon insertion, especially when arch anatomy varied. By dividing the shell into three sections, fit is far more reliable — no model, no index, just print and place.

There are two tooth-colored resins available from Formlabs Dental to print using Form 4B: Premium Teeth Resin and BEGO™ VarseoSmile^Ⓡ TriniQ^Ⓡ Resin. The differences of these two materials can be found in the following table.

For printing the shells, Premium Teeth Resin is the recommended choice as it provides translucency and natural aesthetics, especially in the B1 shade. The results out of the printer are already impressive, with a nice surface finish that polishes nicely with minimal effort.

In this case, the shells need to be oriented so that their incisal edges and cusps face towards the build platform. Then, supports can be automatically generated using Support > Auto-Generate All.

Confirm that you don’t have any support structures in undesired areas. You can remove these manually under the Supports menu by clicking Edit and selecting the support you want to remove.

Following nesting in PreForm Dental, the parts are printed and post-processed. The 3D printing workflow involves several steps: printer setup, printing, washing, drying, and post-curing. Total production time varies depending on the layer height chosen for printing.

4.1 Setting up Form 4B 

Insert a build platform, resin tank, resin mixer, and Premium Teeth Resin cartridge in the printer. Once the printer is set up, send the print job from PreForm Dental to the printer.

4.2 Post-processing 

After the print job is completed, the next step to follow is post-processing which includes removing the parts from the build platform, washing, drying, and post-curing. Post-processing of parts printed with biocompatible resins requires following the steps as established in the Premium Teeth Manufacturing Guide.

Wash:

• After parts are removed from the build platform, they need to be washed in IPA (99%) in the Form Wash (2nd Generation) at High Speed for 10 minutes or until clean. It’s important to use a dedicated Form Wash for washing parts printed with Premium Teeth Resin. This Form Wash should not be shared with other materials and the exact timing presented in the Manufacturing Guide should be followed.

• Immediately after washing, dry the printed parts with compressed air to ensure that there is no remaining IPA or resin on the printed part, especially in the intaglio surface. This is critical to ensure proper fit of the shell during the clinical execution.

• Allow parts to air dry at room temperature for at least 30 minutes.

Cure: 

• Parts need to be post-cured in the Form Cure (1st Generation) or Form Cure (2nd Generation) for the specific time and temperature as established in the Manufacturing Guide. This final step will ensure parts are ready to be used clinically. 

The following graphics summarize the overall process and final production time.

4.3 Part Finishing

4.3.1 Support removal: Remove support structures with a cutting disc or very carefully use a pair of high-quality precision nippers to trim off support tips as close to the surface as possible. Grind down the touch points with a dual-cut carbide bur.

4.3.2 Polishing: The polishability of parts printed with Premium Teeth Resin is one of the nicest features of this material. You can achieve excellent polishing and high gloss with minimum effort.

• Polish using a flexible diamond disc and Medium polishing paste (e.g. DiaShine®Medium Soft).

• Achieve a high shine using a bristle brush and a fine polishing paste (e.g. DiaShine®Super Fine Soft) to polish the parts.

• Clean the part with a clean wool disc for added shine.

After polishing, the parts are ready to be used clinically.

Once the shell is positioned and secured, continue with the photographic and video documentation.

Despite the minimal thickness, the material strength, translucency, and low opacity provide a highly convincing look that patients instantly connect with.

Once the documentation is completed with the motivational mock-up, the printed shell sections can be easily removed with the explorer tool.

3D printing has removed the barriers that once made mock-up fabrication complex, time-consuming, or inconsistent. With the ability to choose from three streamlined protocols, dental professionals now have full control over materials, time, and workflow — whether it’s selecting the right model resin, or deciding to skip bis-acryl altogether in favor of a high-precision 3D printed shell. The technology is here, it’s accessible, and it’s proven. Today, there’s no reason not to leverage digital tools to deliver fast, clean, motivational and technical mock-ups that elevate patient experience and clinical outcomes. The choice is yours — customize your approach, and let 3D printing do the heavy lifting.