3D Printing Surgical Guides

SprintRay’s Surgical Guide Resin allows you to print accurate surgical guides for dental implants. It is a biocompatible photopolymer resin with high strength and excellent dimensional accuracy. In this workflow guide we will cover the following topics: Best Practices for 3D Printing Surgical Guides & Cleaning and Post Processing

 

In this workflow guide we will cover the following topics:

  • Best Practices for 3D Printing Surgical Guides
  • Cleaning and Post Processing

 

Step 1

Treatment Planning and Surgical Guide Design

Implant Treatment Planning

Implant surgical guides are a dental appliance that is used to assist the clinician in placing dental implants in the preoperative designed location. In order to design this dental appliance, a few items are required:

1. DiCom Scan of Patient’s Oral Anatomy: This scan is captured via a dental CBCT system.

2. Digital Impression: This data can be captured by an intraoral impression scanner or a desktop impression scanner.

3. A treatment planning software that comes with .STL file export capability.

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Surgical Guide Design & Export

Once the guide design is finalized, create an .STL or .OBJ file format from the fully designed guide. Below are some implant guide softwares compatible with MoonRay

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Step 2

Print Preparation in Software

Import the surgical guide model into SprintRay Software to set up the print. Recommended layer thickness for surgical guides is 100 microns. Note that they can be printed at 50 microns, but this will slow the print time.

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Setting Up Accurate Prints

To print precisely with SprintRay Surgical Guide resin, it is important to orient the model such that no support structures are generated on guide sleeve holes or surfaces. This ensures accuracy of the fit.

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Step 3

Printing on MoonRay

Before you begin printing, shake the SprintRay Surgical Guide Resin bottle to ensure complete mixture of the resin’s chemical formulation. Fill the tank with the resin while being mindful of the minimum and maximum fill lines. Now the print can begin.

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If there is leftover resin in the tank from the previous print, use the provided resin wiper to stir the resin before printing. This ensures that the resin is properly mixed and clean.

Maintaining the Resin Tank Drum

When cared for properly, the resin drum in MoonRay is designed to last for 50 liters of use. Resin left over after a print can be left in the tank for up to 24 hours. However, note that prolonged exposure to bright lights and air may inadvertently cause it to begin curing. It’s therefore recommended that you pour extra resin back into the bottle and clean the tank within 24 hours. To clean, gently use a paper towel and isopropyl alcohol to wipe the interior. Avoid using a coarse cloth or sharp tools to loosen cured resin from the tank, as this may cause damage. After 50 liters of use, the tank may become cloudy, causing your models to peel. If this happens, replace your resin tank to ensure continued print accuracy

Step 4

Post-Processing

After printing, models must be rinsed, dried, removed from support structure and then post-cured. Read the following for detailed instructions on how to effectively post-process the surgical guide model.

Washing Parts

Bathe the surgical guide model in a bath of 96% isopropyl alcohol (IPA) to remove any liquid resin. Use a toothbrush to scrub the surface of the model to remove any partially-cured resin.

Once the majority of the resin is removed, transfer the model into an ultrasonic cleaner filled with clean IPA for no more than 5 minutes. For this process, orient the occlusal surface of the model downward to allow resin to fall away during the agitation process.

In total, the print should spend no more than 10 minutes in alcohol to avoid micro-cracks and abrasions. Once cleaned, air-dry the print using compressed air. If there are any particles or residue still on the model, spray it down with more alcohol. Rinse, dry, and repeat until all uncured resin is removed.

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Removing Supports

Manually snap-off or use a flush cutter to snip off the support structure from the surgical guide. Using the flush cutter included in the finishing kit, cut the supports as close as possible to their attachment points on the surgical guide. Be careful not to nick the surgical guide itself, as this can cause pitting that may be difficult to remove during sanding.

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Post-Curing Requirements

The surgical guide must be properly post-cured to manufacturer’s specifications before use. The color of the model will change from translucent yellow to a translucent pink during the post-curing process. Recommended minimum postcure time is between 15-25 minutes depending on the specification of your curing unit.

Polishing Printed Guides (Optional)

To ensure a smooth surface finish, take a small file and sand away small nubs left over by the support structure. Sand in a circular motion to remove the nubs without leaving deep sanding marks; the goal is to blend the nubs into the surface of the print. Once finished, use high grit sandpaper to blend the sanded areas. To achieve a polished look, apply chapstick to mask the sanding scratches.

Assembly

Insert the guide sleeves into printed parts prior to sterilization.

Sterilization

Sterilize printed Dental Surgical Guides parts in an autoclave after fully rinsing, drying, post-curing, and assembling. A sterilization pouch is optional. If disinfection is required, use non-chemical products. If this is not possible, ethanol solution is recommended for disinfection purposes.

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Downloadable SprintRay Surgical Guide Workflow

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