3D Printing in Dentistry

For years, 3D printing seemed like a futuristic concept straight out of science fiction. You might recall scenes from childhood cartoons where characters printed meals at the push of a button. Today, while the technology no longer feels like magic, it still hasn't become an everyday household tool—and in medicine, it's often seen as something reserved for cutting-edge research, used for printing organs and implants in highly specialized settings.

Dentistry, however, is an exception. 3D printing has already become an integral part of modern dental practice. Let’s explore how this technology is shaping the future of dentistry.

What is 3D Printing in Dentistry?

3D printing in dentistry refers to the use of additive manufacturing to create dental appliances, models, and restorations directly from digital designs. 

3D printing is an additive process. It means that objects are built layer by layer from resins or powdered materials. However, dentistry often groups it together with subtractive manufacturing (milling) due to their similar workflows and integration within CAD/CAM systems. Subtractive manufacturing involves carving restorations from solid blocks of material, such as zirconium dioxide crowns, while additive methods create dental models and surgical guides by solidifying liquid or powdered materials layer by layer.

Despite their technical differences, both technologies are widely used in digital dentistry, working together to enhance precision, efficiency, and customization in modern workflows.

How 3D Printing Works in Dentistry

3D Printing Workflow 

3D printing in dentistry relies on CAD/CAM (Computer-Aided Design and Computer-Aided Manufacturing) technologies, which convert digital patient records into 3D virtual models and further into 3D-printed dental models, appliances, and restorations. The process follows a structured workflow, starting with digital data acquisition and progressing to the physical fabrication of dental objects.

Step 1: Digital Data Collection

The foundation of 3D printing in dentistry is accurate digital scanning of the patient’s oral structures. This is achieved using:

• Intraoral Scanners (IOS) – Handheld devices that capture high-resolution digital impressions of teeth and soft tissues. These scanners eliminate the need for traditional PVS (polyvinyl siloxane) impressions.

• CBCT (Cone Beam Computed Tomography) – Used when bone structures need to be addressed, such as in implant planning or maxillofacial applications. CBCT generates volumetric 3D images, which can be converted into printable models.

Step 2: CAD – Digital Design and Preparation

Once the scan data is collected, it is processed using CAD software, which allows for:

• Reconstruction of patient-specific 3D models from intraoral and CBCT scans

• Precise customization of restorations, aligners, surgical guides, or dentures

• Simulation and optimization of fit before printing

Step 3: CAM – 3D Printing the Object

After the digital design is finalized, the file is sent to a 3D printer, where the object is built layer by layer using various additive manufacturing techniques. The type of 3D printer used depends on the required material and application. See further section for more information on different technologies. 

Once printed, the object undergoes post-processing, which includes washing (for resin-based prints), curing under UV light and final surface finishing, removing supports and other extra material.

3D Printing Technologies in Dentistry

Different types of 3D printing technologies are used in dentistry, each suited for specific applications:

Stereolithography (SLA): Uses a laser to cure liquid resin layer by layer, offering high precision and smooth surface quality. Commonly used for models, surgical guides, and splints.

Digital Light Processing (DLP): Similar to SLA but uses a digital projector instead of a laser, allowing faster printing speeds. Ideal for high-volume production of dental models and temporary restorations.
PolyJet Printing: Works like an inkjet printer, jetting and curing multiple materials simultaneously. Enables multi-material, color, and flexible prints for lifelike dental models.

Selective Laser Sintering (SLS) & Electron Beam Melting (EBM): Powder-based methods that fuse particles with a laser or electron beam, typically used for metal restorations like crowns and dental implants.

3D Printing in Aligner Production

Clear aligners rely on precise 3D printing dental technology, transforming digital scans into a series of step-by-step treatment models. Aligners work by gradually shifting teeth through a sequence of printed models, each representing a slightly adjusted position of the dentition.

Step 1: Digital Data Collection

The process begins with gathering accurate patient data, which includes:

• Intraoral Scans – High-resolution scans capture the patient’s current dental anatomy.

• CBCT (if required) – Used for cases involving root positioning or bone structure analysis.

• Photographs – Aid in aesthetic evaluation and treatment planning.

Step 2: Virtual Treatment Planning

Specialized CAD software—for example, eXceed, is used to create a virtual setup. Treatment plan maps out how the teeth will move over time, step-by-step. This stage includes:

• Simulating tooth movements toward the final alignment.

• Defining staging – the number of steps (aligners) needed for the full correction.

• Doctor’s refinements – Adjusting movements, placing attachments, and ensuring proper force distribution.

Once the doctor approves the treatment plan, the digital files are ready for model fabrication.

Step 3: 3D Printing the Models

Each treatment step corresponds to a separate 3D-printed model, representing incremental changes in tooth positioning. The models are printed using resin-based 3D printers (SLA or DLP technology) for high accuracy.

Commonly used printing methods include:

• Vertical printing without supports – Saves material but may not be suitable for all cases.

• Angled printing with supports – Uses more resin but ensures greater stability and accuracy.

After printing, the models go through post-processing.

Step 4: Thermoforming the Aligners

Aligners are not printed directly. Instead, a thin plastic foil is vacuum-formed over each model using a thermoforming machine. The result is a series of aligners, each designed to apply gentle force and guide the teeth toward the desired position.

Step 5: Final Processing

After thermoforming, the aligners undergo trimming and polishing to remove excess material. Sharp edges and rough areas are smoothed to ensure patient comfort.

Step 6: Chairside Adjustments

For cases requiring attachments, they are placed directly on the teeth using the matrix aligner (aligner #0) as a positioning guide. Attachments are made using dental adhesive and composite cured by UV light.

Applications of 3D Printing in Dentistry

Orthodontics

3D printing dental technology has completely changed orthodontics, making treatment planning and appliance production faster and more precise. Instead of traditional impressions, orthodontists now use digital models to create aligners, retainers, and bonding trays for braces with greater accuracy and less manual work.

Without 3D printing, clear aligners wouldn’t be possible because traditional plaster models are static—they can’t simulate or predict tooth movement. Digital dentistry technologies allow orthodontists to plan each stage of alignment with precision, visualizing how teeth will shift over time.

3D printing is also used for indirect bonding trays, which make bracket placement quicker and more accurate. By combining digital planning with 3D printing, orthodontists gain more control over treatment.

Restorative Dentistry

Dental 3D printing plays a crucial role in restorative dentistry by enabling the production of highly accurate diagnostic models and mock-ups. These models help dentists refine treatment plans and provide patients with a clear visualization of the expected outcomes. By using digital scans, clinicians can create precise 3D-printed replicas of the patient’s dentition, improving communication and treatment predictability.

Prosthetics

3D printing enhances the fabrication of both temporary and permanent crowns, bridges, and other dental prosthetics. High-precision resins and ceramic-based materials allow for restorations with superior marginal fit, minimizing the need for post-processing adjustments. The digital workflow upgrades production, enabling faster turnaround times while maintaining a high degree of customization for each patient.

Surgical Guides

3D-printed surgical guides improve the accuracy of implant placement, complex extractions, and bone grafting procedures. Designed using CBCT scans, these guides ensure that surgical instruments follow the planned trajectory with minimal deviation. This reduces the risk of complications, shortens procedure times, and improves patient outcomes. The ability to customize guides for each case ensures optimal results, particularly in cases requiring precise angulation and depth control.

Dental Implants

Additive manufacturing enables the production of custom implant components, including abutments and frameworks. A major advantage is the ability to create porous or bone-like implant surfaces that may improve osseointegration. While subtractive manufacturing techniques such as milling are still used for final refinements, 3D printing allows for the creation of complex geometries that would be difficult to achieve through traditional methods. This results in better integration with the patient’s bone structure.

OMF Implants

For patients requiring oral and maxillofacial (OMF) implants, 3D printing offers a solution for creating highly customized, patient-specific implants. These implants restore facial structure and functionality, particularly in cases of trauma or congenital defects. Titanium and biocompatible polymers such as PEEK (polyether ether ketone) are commonly used materials.

Benefits of 3D Printing in Dentistry

Speed and Efficiency

Additive manufacturing in dentistry reduces production time for models, aligners, crowns, and surgical guides. What once took days or weeks can now be completed in hours, minimizing patient wait times.

Precision and Customization

Every printed model or appliance is tailored to the individual patient, ensuring a perfect fit. The accuracy of digital workflows eliminates manual errors and improves treatment outcomes.

Cost Savings

By bringing production in-house, dental professionals can lower laboratory expenses and control costs more effectively. They only print what’s needed, reducing material waste and unnecessary expenditures.

Improved Patient Experience

Digital impressions and 3D-printed models replace uncomfortable traditional molds, making the process more convenient for patients. Faster turnaround times mean they receive their appliances sooner.

Enhanced Treatment Planning

With 3D printing, dentists and orthodontists can visualize and test treatment options before proceeding. Surgical guides and digital setups improve accuracy in complex procedures, leading to better and more predictable results.

Versatility in Applications

From orthodontics to implantology and prosthetics, 3D printing supports a wide range of dental treatments. It allows for on-demand production of models, guides, restorations, and even biocompatible 3D printed dental implants.

The Future of 3D Printing in Dentistry

3D printing in dentistry is advancing rapidly, with AI-powered software optimizing treatment planning and automating production. This will enhance precision, customization, and efficiency in everything from aligners to implants.

As technology becomes more accessible, more clinics will integrate in-house 3D printing, reducing costs and treatment times. New materials and faster printers will further improve accuracy and durability, making high-quality dental care widely available.