3 D printing dental frame-protheses

3D Bioprinting Conference19 June 2014 MECC Maastricht 1

3 D printing dental frame-protheses

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Manual production to digital production

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manual designfor casting

digital design for 3D printing

import for printer

• less hand labor

• more flexibility

• more precision

• constant quality

• optimum design possible

• no chance of air inclusions

Advantages digital processvs hand made lost wax casting

3D Bioprinting Conference19 June 2014 MECC Maastricht

• design is digital so easy to store

• economics of scale possible

• more easy to train staf

• staf is wider deployable

• CoCr and Titanium is possible

• more production capacity available

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Classic Workflow Dentinno Workflow Dentinno Workflow 201..... ????

1 Dentist takes an imprint 1 Dentist takes an imprint 1 Dentist takes a scan in the Mouth

2 Making a plaster model of the imprint 2 Lab makes a plaster model of the print

3 Making a silicone model 3 lab scans the plaster model

4 Making a cast base

5 Making a Wax model by hand 4 Lab makes a digital design with a 3D CAD Program 2 Lab makes a digital design with a 3D

CAD Program

6 Bringing cast channels

7 embeding the wax model with refractory material

8 Melting the wax in the oven

9 Casting metal in mould 5 Dentinno 3D print the partial 3 Dentinno 3D print the partial

10 extracting the frame out of the mould

11 cutting of the cast channels

12 grinding the partial

13 Polishing the partial 6 Dentinno finishes the printed partial 4 Dentinno finishes the printed partial

14 completing the partial with teeth 7 completing the partial with teeth 5 completing the partial with teeth

15 delivery to the dentist 8 delivery to the dentist 6 delivery to the dentist

16 Dentist fit the partial by the patient 9 Dentist fit the partial by the patient 7 Dentist fit the partial by the patient

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production process dental lab / Dentinno

3D Bioprinting Conference19 June 2014 MECC Maastricht

Dental Lab scans the plaster model

Dental Lab makes the 3D design on the computer and sends the STL file to Dentinno

Dentinno produces the partial by SLM

Dentinno polishes the partial in mirror Finnish

Dental lab completes the partial with teeth

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• frame technician saves time ( ± 1,5 hours Per partial ) Average number of frames per frame technician per day increased from 4 to 16.

• less use of metal, hardly no waste

• no waste of duplication materials

Savings with the digital process:

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Production process Dentinno

3D Bioprinting Conference19 June 2014 MECC Maastricht

planning production on SLM machine

SLM production

Heat treatment

partial removal from the building plate

pre grinding

high frequent polishing

quality control and shipment to the dental lab

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3D Bioprinting Conference19 June 2014 MECC Maastricht

Building plate with 3 D printed partials

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3D Bioprinting Conference19 June 2014 MECC Maastricht

The production proces

Design

3 D print

Polished

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• 3Shape (Denmark)

• Dental Wings (Canada )

Design software

3D Bioprinting Conference19 June 2014 MECC Maastricht

Availeble software for design Partials :

• Digilea (France)

• Sensible / Freeform (US)

Dentinno can train the personal for the digital designing

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Conditions for a good 3D design :

3D Bioprinting Conference19 June 2014 MECC Maastricht

• The quality of the plaster model should be very good. 

• There should be no failures in the scan .

• Pay much attention to the fine-tuning by making the design (this takes a lot less time then post processing).

Attention:  De designer makes the difference in the final quality

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3D Bioprinting Conference19 June 2014 MECC Maastricht

A good plaster print without errors is a prerequisite for a good fit

a failure in the plaster model will be scanned and

printed in the partial

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3D Bioprinting Conference19 June 2014 MECC Maastricht

Designing a denture

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• Dentinno uses the latest generation metal-laser printers.

• We produce frames with the same flexibility as casted frames.

• Metal alloy powder is similar to the casting CoCr-metal that is used.

Selective Laser Melting

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3D Bioprinting Conference19 June 2014 MECC Maastricht

Which metals are available for SLM ? • Stainless steel◦ 316L (1.4404)◦ 17-4 (1.4542)◦ 15-5 (1.4540) – Hardenable 45 HRC

• Tool steel◦ Maraging X3NiCoMoTi 18-9-5 (1.2709) – Hardenable 54 HRC

• Titanium◦ Ti commercially pure – Grade 1 – Very pure Ti, very ductile◦ Ti commercially pure – Grade 2 – Very ductile◦ Ti6Al4V ELI – Grade 23 – Almost identical to grade 5◦ Ti6Al4V ELI medical quality – Grade 23◦ Ti6Al4V – Grade 5 – High strength◦ Ti6Al4V medical quality – Grade 5

• Superalloy◦ CoCrMo-LC – ASTM F75 – implants, high strength◦ CoCrWMo – Dental◦ Inconel 718 – NiCr19FeNbMo3

• Aluminium◦ AlSi10Mg, AlSi12

• Materials under development & custom development possible 16

Animation 3 D metal-printing

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Examples industrial 3D metal printing

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Examples medical 3D metal printing

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3D Bioprinting Conference19 June 2014 MECC Maastricht

Demo film SLM Selective Laser Melting

A product is made up of slices (layers)The layers have a thickness of 30-60 micron

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Conditions for 3D printing

3D Bioprinting Conference19 June 2014 MECC Maastricht

You need a STL file of the desired product

How you get an STL file ?

- by a CAD drawing - by a scan of an existing product ( reverse engineering )

Design Rules :

- no limitations compared to machining- in metal printing you need supports so the position on the building plate is important - smooth designs need less supports

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

Removing the products of the base plate and removing the supports

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Post treatment SLM products

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Possible post treatments :

1 - sand blasting 2 - trumbling3 - cnc machining4 - grinding / polishing by hand 5 - high frequent polishing

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

Sandblasting

Advantages :- simple and quick process - not expensive

Disadvantages :- dull surface- no precision - still a rough surface

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

Trumbling

Advantages :- simple proces - not expensive

Disadvantages :- slow process- irregular decrease especially by strongly profiled products- not all spots are accessible

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

Machining

Advantages :- high precision

Disadvantages :- difficult to program - expensive

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

Manual grinding and polishing

Advantages :- high quality possible - selective treatment possible

Disadvantages :- hand-labor, expensive- skilled personel needed- not a “clean” job - no constant quality

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Post treatment SLM products

3D Bioprinting Conference19 June 2014 MECC Maastricht

High frequent polishing ( development by Dentinno )

Advantages : - fast process- complexe shapes possible- environmental friendly - mirror finish

Disadvantages :- high energy consumption ( electricity )

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Developments in the (near) future

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Wenn the mouth scanner is introduced at the dentist the only production method than is the digital one

Developments in the (near) future

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3 D printing the gums and teeth ass well

printing is already possible but the proper material is not available yet and the design software is not ready yet

Questions ? 3D Bioprinting Conference19 June 2014 MECC Maastricht 31