3D printing provides a new way to fabricate dentures that are strong, aesthetic, and
comfortable. With SprintRay in your office, you can deliver dentures in fewer appointments while
providing an exceptional patient experience. This guide will walk you through the process of
gathering data, fabricating, and placing a removable denture.
Denture Workflow at a Glance
1. Capture Data
- Determine Denture Type
- Copy or Reference Denture
- New Denture
- Immediate Denture
2. Submit Design Request
- Submit Treatment request
- Review and Approve Design
3. Create Print Jobs
- Importing into RayWare
- Sending to printer
4. 3D Print and Wash Denture Base
- Preparing printer
- Wash the Denture Base
- Remove Supports
5. 3D Print and Wash Denture Teeth
- Preparing printer
- Wash the Denture Base
- Remove Supports
6. Assemble and Post Cure
- Assemble the Teeth and Base
- Cure in Pro Cure 2
7. Smoothen and Polish
- Smoothen with Handpiece
- Polish with Dental Lathe
- High Shine with Mineral Oil
- Clean
Workflow Deep Dive
1. Capture Data
Determine Denture Type
SprintRay offers a full workflow for 3 main types of removable dentures. Depending on which denture you need, the patient data required and the files you receive will vary.
Denture Types
- Copy or Reference Denture
- Use an existing denture to create an exact replica or slightly adjusted prosthetic with improved retention and aesthetics
- New Denture
- For an edentulous patient who does not currently have a denture. A conventional wax rim impression is required for this treatment
- Immediate Denture
- Create a temporary denture to be placed immediately after a patient has had their teeth extracted
Note: The fabrication process for all the major denture types is similar; most of the
difference between denture types is the data you'll need to submit for design.
Copy or Reference Denture
Copy and reference dentures use the patient's existing prosthetic as the basis for designing a replacement.
Use an intraoral scanner to directly scan the occlusal, palatal, and intalgio surfaces of the
denture. If possible, include all surfaces of the denture in the same scan. If retention is poor, use
the existing denture as a custom impression tray to take a functional impression.
New Denture
New dentures are for patients who are already edentulous and don't already have a denture.
Take a conventional wax rim impression, then use an intraoral scanner or benchtop scanner to
digitize. If using an intraoral scanner, directly scan the occlusal, palatal, and intaglio surfaces of
the impression. If possible, include all surfaces of the impression in the same scan.
Immediate Denture
Immediate denture is for a patient who currently still has teeth and requires a temporary
prosthetic for use after extraction.
Perform a pre-op scan of the patient's current anatomy. Scan as much of the gingiva as
possible. Scan the depth of the sulcus if possible.
Note: This is a temporary appliance; the patient should return when fully healed for a
reference or copy denture.
2. Submit Design Request
Submit Treatment Request
Visit dashboard.sprintray.com and sign in or sign up for a SprintRay account. Select or add your
patient, then choose the 'Removable Dentures' treatment type and select the subtype you chose
in Step 1. Upload all relevant data.
Review and Approve Design
In-Office Design
For the design and treatment planning of denture bases and complete digital dentures we recommend the following certified programs for use:
As a general recommendation, we recommend the following design parameters for best success;
Minimum Thickness
- Upper- 2.5 mm
- Lower - 3 mm
Flange Height
- 2-3 mm from depth of vestibule
Teeth Offset (adhesive space)
- 0.100 mm
3. Create Print Jobs
Import into RayWare
Navigate to RayWare Cloud, then start a new print job. Since a denture consists of teeth and a
base printed separately, you'll need to set up two print jobs. Depending on the denture type, you may also be provided a Try-In denture as well.
Recommend Print Settings:
| Denture Base | Denture Teeth | |
| Type | Prosthetics → Base | Prosthetics → Teeth |
| Material | High Impact Denture Base | High Impact Denture Teeth |
| Thickness | 100 microns | 100 microns |
| Orientation | Intaglio surface facing towards the build platform, anterior angle at a 60° angle | Occlusal surface facing toward and parallel to the build platform |
Queue to Printer
Once you're happy with the setup of your print, select the Send to Queue button, then choose the printer you'd like to use for this print job.
Note: You can also use the Print Now button, but be sure to thoroughly inspect your printer
before you start printing.
4. 3D Print and Wash Denture Base
Prepare and Start the Print Job
- Check that the platform is clean and ready
- Check that the resin tank is seated in its cradle
- Fill the tank to the max line with Denture Base resin and mix to incorporate
- Go to the Queue and press Start Print
- You can monitor progress on the touchscreen or on SprintRay Cloud. The print job should take around 60 minutes
Wash the Denture Base
- Transfer the build platform to ProWash
- Run a standard cleaning cycle
- Remove the denture base from the platform
Remove Supports
Twist the supports away from the denture. Use the support snipper if they don't come away easily.
5. 3D Print and Wash Denture Teeth
We will be doing the same process to prepare the printer that we used previously, only this time we will be using the Denture Teeth resin instead.
Prepare and Start the Print Job
- Check that the platform is clean and ready
- Check that the resin tank is seated in its cradle
- Fill the tank to the max line with Denture Base resin and mix to incorporate
- Go to the Queue and press Start Print
- You can monitor progress on the touchscreen or on SprintRay Cloud. The print job should take around 60 minutes
Wash the Denture Teeth
Note: If you are printing denture teeth with a high-ceramic material such as Ceramic Crown or
OnX, consult the IFU for washing instructions
Remove Supports
Carefully twist the supports away from the denture teeth. Use the support snipper if they don't come away easily.
6. Assemble and Post Cure
Note: If you are creating the denture base and teeth from two different resin lines, first select
Conventional Denture on ProCure 2 and follow the onscreen instructions for assembly
and curing
Assemble the teeth and Base
- Use a syringe to cover each socket with denture base resin
- Press the teeth and base firmly together, applying level pressure
- Continue applying pressure while tack curing the teeth and base together
Cure in ProCure 2
- Place the assembled denture in the ProCure 2
- Select Conventional Denture on the touchscreen and follow the onscreen instructions for curing
7. Smoothen and Polish
Required Tools:
Smoothen with Handpiece
Use low RPM with a Red Fuzzies and/or a carbide burr to remove any stumps left over from supports. Make sure to do a full pass along occlusion.
Smoothen with Resilience
Use a black bristle wheel B27/B29 and Resilience polish. Resilience should be wet but not
runny. Apply medium pressure.
Note: Polish at low speed and do not let the wheel dry out
Apply Tripoli Rouge
Apply Tripoli to a Robinson #11 wheel on a lab handpiece in hard-to-reach places and interproximal surface.
Note: Do not let the wheel dry out
Polish with White High Shine
Use a fresh wheel and White High Shine to polish all surfaces of the denture using full
pressure.
Note: Polish at low speed and do not let the wheel dry out
Apply Mineral Oil
Dip a gloved finger in mineral oil and smear across the denture surface.
Remove White High Shine
Use medium/heavy pressure on a new Robinson #11 wheel to reach all the interproximal areas, removing mineral oil and White High Shine so the denture is shiny.
Note: Do not let the wheel dry out
Clean
Remove residual mineral oil and brush denture by hand, use a steamer, or rinse with water. Dry with compressed air and/or a blue shop towel.
Disinfect and then place the denture.