Question 1

Why does my intraoral scanner lose tracking or stop mid-scan?

Accepted Answer

Tracking loss usually occurs when the scanner cannot find enough unique surface geometry to stitch images together. Ensure teeth are dry, avoid excessive saliva pooling, and move the scanner slowly and steadily. Scanning over large flat or featureless areas (like edentulous ridges) is especially prone to tracking loss, consider adding scan powder or artificial landmarks.

Question 2

What causes blurry or low-detail margins in my digital impression?

Accepted Answer

Poor margin capture is almost always due to inadequate tissue retraction, moisture contamination, or blood in the sulcus. Pack retraction cord before scanning, ensure the field is completely dry, and verify you can see 0.5mm sub-marginally before scanning. If you cannot see the margin clearly on screen, your lab will not be able to detect it either.

Question 3

How does saliva or blood affect scan accuracy?

Accepted Answer

Scanners rely on light reflection to capture surface geometry, and shiny or wet surfaces create artifacts and distortions. Saliva causes specular reflections that confuse the scanner's algorithms, while blood obscures preparation margins. Use high-volume suction, retraction cord, and hemostatic agents to maintain a dry field throughout scanning.

Question 4

Why does my lab keep rejecting my digital scans?

Accepted Answer

The most common rejection reasons are unclear or missing margins (often the leading cause of rejections), incomplete arch data, distorted bites and stitching artifacts. Labs review incoming scans for margin clarity, completeness of data, bite alignment and stitching artifacts. Many labs now use AI-assisted scan-quality tools such as SmileShape SmartScan, which flag issues like missing margins, inadequate interproximal data or poor bite alignment for a technician to review, catching problems before design starts and reducing costly remakes.

Question 5

What is scan stitching error and how do I prevent it?

Accepted Answer

Stitching errors occur when the scanner's software incorrectly aligns overlapping image segments, creating subtle distortions in the 3D model. These small errors can snowball into open contacts, high occlusion, and remakes. Avoid overscanning the same area repeatedly, move the scanner at a consistent speed, and review the final model for any visible distortions before submitting to the lab.

Question 6

Does ambient lighting affect my scan results?

Accepted Answer

Yes. Most intraoral scanners use structured light or laser-based technology, and strong overhead dental lights can interfere with the scanner's light source. Turn off or dim the dental lamp during scanning. Some scanners like 3Shape TRIOS explicitly recommend not using the dental lamp while scanning.

Question 7

How do I know if my scan is accurate enough before sending to the lab?

Accepted Answer

Check for complete margin visibility around the entire preparation, verify interproximal contact areas on adjacent teeth are fully captured, confirm the bite registration shows realistic occlusal contacts without artificial gaps or collisions, and ensure no areas are flagged as incomplete by the scanner software. Most modern scanners highlight missing areas in color after scan completion.

Question 8

Why does my scanner fog up during use?

Accepted Answer

Fogging occurs when the scanner tip is cooler than the patient's intraoral temperature, causing condensation. Most modern scanners include anti-fog features, for example, 3Shape TRIOS recommends waiting for the tip to heat up before scanning, and the Shining 3D Aoralscan 3 has a built-in fan for fog prevention. Some clinicians briefly warm the tip with their fingers or use a warm water rinse before starting.

Question 9

What are the top 5 most common intraoral scanning mistakes?

Accepted Answer

The five most common preventable mistakes are: (1) inadequate tissue retraction leaving margins obscured, (2) insufficient moisture control, (3) poor preparation design with unclear finish lines, (4) incomplete or inaccurate bite registration, and (5) overscanning the same area which creates overlapping data and stitching errors. Addressing these five areas dramatically reduces remake rates.

Question 10

How often should I calibrate my intraoral scanner?

Accepted Answer

Calibration frequency varies by brand. Medit i900 recommends calibration every three months. DEXIS IS 3700 and IS 3800 are designed to be calibration-free unless physically dropped or damaged. 3Shape TRIOS has built-in calibration checks. Always recalibrate after any physical impact to the scanner, and follow the manufacturer's specific maintenance schedule.

Question 11

What scanning strategy works best for 3Shape TRIOS?

Accepted Answer

3Shape recommends starting with the occlusal surface and then capturing buccal and lingual surfaces in a smooth, continuous motion. Do not use the dental lamp during scanning, wait for the scanning tip to heat up to prevent fogging, and dry teeth thoroughly before starting. Missing areas are highlighted in color after completion and should be rescanned slowly with the scanner positioned closer to the tooth.

Question 12

My 3Shape TRIOS is lagging or running slowly. What should I check?

Accepted Answer

First, ensure your PC is from the 3Shape approved PC catalog, as non-certified hardware is a leading cause of performance issues. Check for pending Windows updates running in the background which overload the system. Also verify that the scanner firmware and TRIOS software are fully up to date, outdated software versions are a common cause of lag.

Question 13

What are 3Shape DCM files and can I edit them later?

Accepted Answer

DCM is 3Shape's proprietary scan format used within Dental System, Ortho System, and Implant Studio. Raw scan data called 'streams' are converted into DCM files after post-processing. If streams are deleted, you lose the ability to make further edits and can only work with the finalized DCM files. DCM files can be exported to STL or PLY for use in third-party CAD software.

Question 14

Why does my Medit scanner keep disconnecting?

Accepted Answer

Connection drops on Medit scanners are most commonly caused by damaged USB cables or using third-party cables instead of the included Medit USB 3.0 cable. For the i900, verify your computer's USB-C port supports Power Delivery (PD), without PD support, the i900 cannot function. Also check that your system meets Medit's minimum PC requirements and that no other resource-heavy applications are running.

Question 15

My Medit scanner says 'No Tip', what do I do?

Accepted Answer

The Medit i600, i700, and i700 wireless have a proximity sensor at the tip mounting area. First, clean the sensor area gently, oil or fingerprints can interfere with detection. Test by covering the sensor with your finger without pressing hard. If the 'No Tip' status persists after cleaning and reinserting the tip, the proximity sensor itself may be faulty and require service.

Question 16

What is the difference between Medit i700 and i900?

Accepted Answer

The i900 offers faster scan speeds, higher accuracy, and uses a USB-C connection (requiring Power Delivery support). The i700 uses a standard USB 3.0 connection and is a proven workhorse scanner. The i900 requires calibration every three months, while the i700 has less frequent calibration needs. Both export open STL files and work with Medit's free scanning software.

Question 17

Is the iTero scanner only for Invisalign cases?

Accepted Answer

No. While iTero has deep integration with Invisalign and is the primary scanner used for Invisalign treatment planning, iTero Element and Lumina scanners are fully capable restorative scanners. They can capture digital impressions for crowns, bridges, implants, and other prosthetics, and export files to any dental lab. The Invisalign integration is an added benefit, not a limitation.

Question 18

How fast is the iTero Lumina compared to the Element 5D?

Accepted Answer

The iTero Lumina is designed to be significantly faster than the iTero Element 5D imaging system. Both capture high-resolution 3D scans, but the Lumina's improved speed reduces chair time and improves patient comfort. Exact scan times vary by case complexity and arch completeness.

Question 19

Why does my iTero require a subscription?

Accepted Answer

iTero operates on a subscription-based model. The subscription covers regular software updates, technical support, cloud storage for patient scans, and access to features like the Invisalign Outcome Simulator. Hardware and subscription costs vary by model and region, contact Align Technology or an authorized reseller for current pricing.

Question 20

Does the DEXIS IS 3700/3800 need regular calibration?

Accepted Answer

The DEXIS IS 3700 (formerly Carestream CS 3700) and IS 3800 are designed as calibration-free scanners under normal operating conditions. Calibration is only needed if the scanner experiences physical shock, such as being dropped. Never use a non-DEXIS power adapter, as it may compromise safety and performance.

Question 21

Can I use the Primescan without a CEREC milling unit?

Accepted Answer

Yes. Primescan Connect allows you to use the Primescan purely as an intraoral scanner and send digital impressions to any dental lab. You do not need a CEREC mill to benefit from the scanner. However, the full value proposition of the CEREC system is chairside same-day dentistry, so clinics that only need a scanner may want to compare pricing with more scanner-focused options.

Question 22

Is the Shining 3D Aoralscan 3 accurate enough for crown and bridge work?

Accepted Answer

Yes. The Aoralscan 3 delivers accuracy comparable to mid-range scanners and handles full-arch scans quickly. Its software includes features like undercut analysis, margin line placement, and direct exocad exporting. At a competitive price point, it is one of the most affordable scanners with professional-grade capabilities, making it a popular choice for labs and clinics entering digital workflows.

Question 23

What are common issues with DOF lab scanners?

Accepted Answer

The most frequently reported DOF issues involve software stability rather than hardware. Users report occasional crashes when overscanning beyond suggested boundaries, occlusion alignment being inaccurate, and proximal contact gaps after milling. The scanner hardware itself is reliable, users report years of trouble-free operation. Files save in DOF's proprietary format but convert to STL during the matching process.

Question 24

How does the Planmeca Emerald compare to other scanners?

Accepted Answer

The Planmeca Emerald S scans more than twice as fast as its predecessor, captures true-to-life color impressions, and includes automatic fog prevention. It integrates with Planmeca's Romexis CAD/CAM software for a complete digital workflow. The scanner features a compact design and exports open file formats. It is calibration-free under normal conditions.

Question 25

Is the Launca DL300 a good budget scanner option?

Accepted Answer

The Launca DL300 offers solid scanning performance at a significantly lower price point than premium scanners. It exports open STL/PLY/OBJ files, features a compact lightweight design, and includes free scanning software with no subscription fees. The DL300 Wireless model adds cable-free convenience. While it may lack some advanced features of premium scanners, it handles routine crown and bridge cases well.

Question 26

How do wireless scanners compare to wired scanners for reliability?

Accepted Answer

Wireless scanners offer ergonomic freedom and easier patient access but introduce risks including battery drain mid-scan, Wi-Fi signal drops, and potential data corruption from environmental interference. Wired scanners provide consistent power and data transfer but limit movement. For high-volume practices, wired scanners remain more reliable; wireless models suit practices prioritizing ergonomics.

Question 27

What is the difference between STL, PLY, and OBJ file formats?

Accepted Answer

STL is the most universal format in digital dentistry, it contains only surface geometry (triangle mesh) without color and is accepted by virtually all CAD/CAM systems. PLY includes geometry plus color, texture, and surface normals, making it the most data-rich format. OBJ also supports color and texture but is less commonly used in dental workflows. For lab communication, STL is the safest default choice.

Question 28

What is a DCM file and can my lab open it?

Accepted Answer

DCM is 3Shape's proprietary internal format used within their Dental System software suite. Labs running 3Shape Dental System can open DCM files natively. Labs using exocad or other CAD software will need the scan exported as STL, PLY, or OBJ. 3Shape allows exporting DCM scans to these open formats.

Question 29

What is the difference between an open and closed scanner system?

Accepted Answer

An open system exports scan data in universal formats (STL, PLY, OBJ) that can be used with any CAD software. A closed system locks scans into proprietary formats that only work with specific software. Medit, DEXIS, Shining 3D, and DOF are fully open. iTero and 3Shape TRIOS currently export open files but operate within more controlled ecosystems.

Question 30

Can I use scans from any intraoral scanner with exocad?

Accepted Answer

Yes. Exocad uses an open-platform approach and accepts STL files from any intraoral or desktop scanner. It can also directly import 3Shape's open .DCM and .3OXZ files. Exocad natively reads and writes STL, PLY, OBJ, and 3OXZ formats without requiring file conversion. This makes exocad the most scanner-agnostic CAD platform available for dental labs.

Question 31

Why does my lab say they cannot open the scan file I sent?

Accepted Answer

This typically happens when the scanner exports in a proprietary format that the lab's CAD software does not support. Always confirm your lab's preferred file format before sending. STL is the safest universal option. If using 3Shape TRIOS, ask whether your lab uses 3Shape Dental System (which reads DCM natively) or exocad/other software (which needs STL or PLY export).

Question 32

Should I send color scans (PLY) or monochrome (STL) to my lab?

Accepted Answer

Color scans (PLY or OBJ) help lab technicians visualize soft tissue, identify margin lines, and verify preparation boundaries more accurately. STL files lack color data but are smaller and universally compatible. Send PLY when your lab's software supports it, as the color information significantly aids margin detection and restoration design. If unsure, ask your lab, most modern labs prefer color scans.

Question 33

What is the best preparation design for digital impressions?

Accepted Answer

A moderate to heavy chamfer finish line is ideal for digital scanning because it creates a clearly detectable margin that both the scanner and the lab's CAD software can identify. Feather-edge margins are difficult for scanners to capture accurately. Polish the preparation smooth, rough surfaces scatter light and reduce scan accuracy. The cleaner and more defined the margin, the better the digital result.

Question 34

How do I capture a proper bite registration with my scanner?

Accepted Answer

Orient the scanner perpendicular to the occlusal table and start scanning as far posterior as possible, moving anteriorly. Capture both sides with at least 3-4 cusp tips visible per quadrant. Retract cheeks and lips to prevent soft tissue interference, which is the primary cause of incorrect bite alignment. Always verify the result in software, checking for artificial gaps or collisions between arches.

Question 35

Do I need to scan the opposing arch for every case?

Accepted Answer

Yes, for any case involving occlusal surfaces. The opposing arch scan allows the lab to design proper occlusal contacts, contours, and functional anatomy. Skipping the opposing arch is a common cause of high restorations and remakes. Even for anterior cases, an opposing arch scan helps the lab verify vertical dimension and incisal edge position.

Question 36

What is overscanning and why is it a problem?

Accepted Answer

Overscanning means repeatedly scanning the same area, which creates overlapping data layers. This confuses the stitching algorithm and can introduce inconsistencies in the 3D model, leading to inaccurate contacts, poor occlusion, or margin distortion. Scan each area once with a slow, steady motion. If an area needs rescanning, use your software's erase tool to delete the bad data before rescanning.

Question 37

Can my dental lab detect scan quality issues before starting a case?

Accepted Answer

Yes. Labs review incoming scans for margin clarity, completeness of data, bite accuracy, and stitching artifacts. Many labs now use AI-assisted scan quality tools like SmileShape SmartScan that automatically flag issues like missing margins, inadequate interproximal data, or poor bite alignment, catching problems before design starts and reducing costly remakes.

Question 38

What is the digital denture workflow and how does it work?

Accepted Answer

The digital denture workflow uses intraoral scanning or scanned conventional impressions, CAD software for denture design (tooth arrangement, gingiva contours, phonetics), and either milling or 3D printing for fabrication. This reduces clinical visits from five to as few as two or three. Many practices use a hybrid approach, combining conventional impressions with digital design to transition gradually into fully digital fabrication.

Question 39

Is milling or 3D printing better for digital dentures?

Accepted Answer

Milling from pre-polymerized PMMA pucks produces denser, more durable denture bases with well-studied material properties and predictable outcomes. 3D printing offers faster production and lower material costs but uses resin materials with less long-term clinical data. Many labs use a hybrid approach, milling the denture base for strength and 3D printing try-ins or temporary dentures.

Question 40

When should a lab use a desktop scanner instead of an intraoral scan?

Accepted Answer

Desktop lab scanners (like Medit T710, DOF Freedom HD, or Shining 3D DS-MIX) provide higher accuracy than intraoral scanners for certain situations: scanning physical models or impressions, digitizing wax-ups, scanning implant models with analogs, or when the clinic sends physical impressions rather than digital files. Desktop scanners also serve as a quality check tool to verify intraoral scan accuracy.

Question 41

What type of scan body produces the most accurate implant scans?

Accepted Answer

Dome-shaped scan bodies produce higher accuracy than cuboid-shaped designs, and titanium scan bodies outperform PEEK (polyetheretherketone) scan bodies in scanning accuracy. The scan body's geometric features give the scanner more reference points for precise position detection. Always use scan bodies from reputable manufacturers that are specifically matched to your implant system.

Question 42

Should I splint scan bodies for multi-implant cases?

Accepted Answer

Research shows mixed results. Some studies found that splinting scan bodies with floss actually increased distance deviation errors. A more reliable approach is the two-step scanning technique: first scan the crest without scan bodies, then place scan bodies and scan again, allowing the software to superimpose the images. This method yields significantly lower precision errors for multi-implant cases.

Question 43

Are intraoral scans accurate enough for implant-supported restorations?

Accepted Answer

For single-unit implant restorations, intraoral scanners provide sufficient accuracy. However, for multiple implant cases, especially screw-retained prosthetics, accuracy diminishes as the span increases. Inter-implant distance significantly affects scanner accuracy. For full-arch implant cases, many clinicians still prefer conventional impressions or use verification jigs to confirm digital scan accuracy.

Question 44

How does implant angulation affect scanning accuracy?

Accepted Answer

Implant angulation directly impacts scan body visibility and the scanner's ability to capture accurate positional data. Severely angled implants make it harder for the scanner to capture the full geometry of the scan body, especially on the lingual or palatal side. For angulated implants, scan slowly from multiple angles and verify the scan body position in the software before submitting to the lab.

Question 45

What is the best scanning strategy for implant cases?

Accepted Answer

Start by scanning the soft tissue and surrounding teeth without scan bodies to establish the baseline arch form. Then place scan bodies, ensuring they are fully seated and finger-tightened, and scan again. The software superimposes both scans for maximum accuracy. Keep the scanner tip clean, move slowly around each scan body from multiple angles, and ensure the entire scan body surface is captured without shadowed areas.

Question 46

Why do full-arch scans have more errors than single-tooth scans?

Accepted Answer

Accuracy decreases as scan length increases because small stitching errors accumulate across the arch. Each image segment introduces a tiny positional error, and over 14+ teeth these compound into clinically significant deviations. Modern scanners generally achieve full-arch deviations under 100 micrometers, which is acceptable for most prosthetic work, but long-span fixed prostheses (5+ units) remain challenging for purely digital workflows.

Question 47

What is the best scanning strategy for a full arch?

Accepted Answer

The continuous scanning technique, starting with occlusal surfaces, then buccal, then lingual in one fluid motion, is most common. An alternative is segmental scanning, where the arch is divided into sections that are scanned individually and stitched together, which can be more accurate for challenging cases. Start from the second molar on one side and work systematically to the opposite side without backtracking.

Question 48

How do I scan an edentulous (toothless) arch?

Accepted Answer

Edentulous arches are challenging because the smooth, featureless ridge lacks the geometric detail scanners need for image stitching. Place artificial landmarks, small adhesive markers, dots, or lines, on the edentulous ridge to give the scanner reference points. Some clinicians use a light dusting of scan spray. Scan slowly and keep the scanner close to the tissue surface for maximum detail capture.

Question 49

Can I use an intraoral scanner for full-arch implant-supported dentures?

Accepted Answer

Yes, but with caveats. For implant-supported overdentures on 2-4 implants, intraoral scanning with scan bodies is generally reliable. For full-arch fixed prostheses on 6+ implants, accuracy challenges increase significantly with inter-implant distance. Many clinicians use a hybrid approach, digital scanning for soft tissue and tooth positions, combined with a verification jig to confirm implant positions before final fabrication.

Question 50

What is the role of AI in digital denture design?

Accepted Answer

AI is increasingly used to automate tooth arrangement, gingiva sculpting, and occlusal scheme design in digital dentures. AI-assisted CAD tools like SmileShape SmartCAD can propose a complete denture design in approximately 2 minutes for a technician to review, adjust, and approve, rather than the hours required to design manually. This dramatically reduces lab turnaround time and addresses the critical shortage of trained CAD designers.

Question 51

What is the difference between 3D printed and milled dental restorations?

Accepted Answer

Milled restorations are carved from pre-manufactured blocks or discs (zirconia, PMMA, lithium disilicate) using CNC milling machines. The source material is industrially produced under controlled conditions, resulting in consistent density and mechanical properties. 3D printed restorations are built layer-by-layer from liquid resin using UV light curing. Printing is faster and produces less material waste, but printed resins generally have less long-term clinical data than milled materials. Most labs use both, milling for final restorations and printing for models, surgical guides, and try-ins.

Question 52

What are the different types of dental zirconia and when should each be used?

Accepted Answer

Dental zirconia comes in several grades. High-strength zirconia (3Y-TZP) offers flexural strength above 1,000 MPa and is ideal for posterior crowns, bridges, and implant frameworks where strength is critical. High-translucent zirconia (5Y-PSZ) provides better aesthetics with lower strength (around 500-700 MPa), suitable for anterior restorations. Multi-layer zirconia discs combine both, stronger at the base transitioning to more translucent at the incisal edge, offering a balance of strength and aesthetics in a single disc. Brands like KATANA, VITA, Ivoclar, and Lava (Solventum, formerly 3M) each offer variations across these categories.

Question 53

What types of 3D printing resins are used in dental labs?

Accepted Answer

Dental 3D printing resins are formulated for specific applications: model resins for diagnostic and working models, surgical guide resins (biocompatible, Class I under US FDA / Class IIa under EU MDR) for implant planning, temporary crown and bridge resins for provisional restorations, denture base resins for removable prosthetics, denture tooth resins for artificial teeth, splint resins for nightguards and occlusal splints, and castable resins for burn-out patterns. Each resin type has specific biocompatibility certifications and post-curing requirements. Always verify that your resin is validated for your specific printer model.

Question 54

What post-processing is required after 3D printing dental parts?

Accepted Answer

Every 3D printed dental part requires post-processing: (1) removal from the build platform, (2) washing in isopropyl alcohol (IPA) or manufacturer-specific solution to remove uncured resin, (3) drying, (4) post-curing under UV light at specified wavelength and temperature to achieve final mechanical properties, and (5) support removal and finishing. Dedicated wash-and-cure units from Formlabs, SprintRay, HeyGears, and Whip Mix automate steps 2-4. Skipping or shortening post-curing is a common mistake that results in weaker, less biocompatible parts.

Question 55

Why does zirconia need sintering and how long does it take?

Accepted Answer

After milling, zirconia is in a pre-sintered (chalk-like) state that is easy to machine but not yet strong enough for clinical use. Sintering heats the zirconia to 1,400-1,600°C, causing the material to densify and achieve its final strength, hardness, and translucency. Traditional sintering takes 6-10 hours. Speed sintering furnaces like the Dentsply Sirona CEREC SpeedFire can sinter a single crown in as little as 10-15 minutes. Sintering also causes the zirconia to shrink by approximately 20-25%, which the CAD software compensates for during the design phase.

Question 56

How do I choose the right milling machine for my dental lab?

Accepted Answer

Key factors include: number of axes (5-axis machines handle more complex geometries and undercuts than 4-axis), spindle speed and power (higher RPM for harder materials like zirconia), material compatibility (wet milling for glass ceramics and metals, dry milling for zirconia and PMMA), automation features (disc changers, bar code scanning for unattended operation), and footprint. Entry-level machines like the Roland DWX-42W suit smaller labs, while production-focused machines like the VHF K5+ or Imes-Icore CORiTEC 350i handle higher volumes. Consider your daily case volume, material mix, and whether you need same-day capability.

Question 57

Can I use any resin with any dental 3D printer?

Accepted Answer

No. Dental 3D printers use specific light wavelengths and exposure parameters that must match the resin's photoinitiator chemistry. Using non-validated resins can result in incomplete curing, poor mechanical properties, or failed prints. Some printers operate as open systems (allowing third-party resins with custom profiles), while others are closed or semi-open. Always check the manufacturer's validated material list. Cross-reference guides, such as printer-material compatibility matrices, help labs identify which resins work with which machines.

Question 58

What equipment do I need for a fully digital denture workflow?

Accepted Answer

A complete digital denture workflow requires: (1) a scanner, either an intraoral scanner or a desktop lab scanner to digitize conventional impressions, (2) CAD software for denture design (tooth arrangement, gingival contouring, occlusal setup), (3) a fabrication method, a milling machine for PMMA bases or a 3D printer for printed denture bases and teeth, (4) post-processing equipment if printing (wash and cure units), and (5) finishing tools for polishing and characterization. AI-assisted design tools like SmileShape SmartCAD can accelerate the CAD step, proposing denture designs in minutes for technician review instead of hours of manual design.

Question 59

What are the main desktop lab scanners available today?

Accepted Answer

The leading desktop lab scanners include the 3Shape E4 (high accuracy, integrates with 3Shape Dental System), Medit T710 (open STL export, free software, strong value), DOF Freedom HD and Freedom UHD (affordable with open file output), and Shining 3D AutoScan DS-MIX (handles models, impressions, and articulators). Desktop scanners provide higher accuracy than intraoral scanners for model and impression scanning, and are essential for labs that receive physical impressions or need to verify digital scan accuracy against poured models.

Question 60

Does SmileShape support information about lab equipment beyond scanners?

Accepted Answer

Yes. SmileShape's AI knowledge base covers equipment across the full digital dental workflow, including 3D printers from brands like Formlabs, SprintRay, HeyGears, and Asiga; milling machines from Roland DG, VHF, Imes-Icore, and Ivoclar; printing and milling materials from dozens of manufacturers; sintering furnaces; and post-processing equipment. This helps labs and clinics get guidance on material compatibility, equipment specifications, and workflow optimization through SmileShape's AI-assisted support.

Question 61

Should I mill or 3D print my denture base?

Accepted Answer

Milled PMMA denture bases (from pre-polymerized pucks) offer superior density, lower residual monomer, and decades of clinical evidence. They are the standard for definitive removable dentures. 3D printed denture bases use photopolymer resins like Lucitone Digital Print or DETAX FREEPRINT denture, they are faster to produce and generate less waste, but long-term clinical data is still being gathered. Many labs mill the final base for durability and 3D print try-ins, immediate dentures, or duplicates where speed matters more than longevity.

Question 62

When should I use lithium disilicate (e.max) versus zirconia?

Accepted Answer

Lithium disilicate (e.g., IPS e.max) offers excellent aesthetics and translucency, making it the preferred choice for anterior crowns and veneers. Its flexural strength (~400-530 MPa depending on Press vs CAD variant) is sufficient for single-unit anterior and premolar restorations. Zirconia provides significantly higher strength (600-1,200+ MPa depending on grade) and is better suited for posterior crowns, multi-unit bridges, and implant frameworks. For cases requiring both strength and aesthetics, labs often use high-translucent or multi-layer zirconia as an alternative to e.max in posterior regions.

Question 63

What makes the Formlabs Form 4B suitable for dental labs?

Accepted Answer

The Form 4B is Formlabs' latest biocompatible 3D printer designed specifically for dental and medical applications. It uses Low Force Display (LFD) technology for fast, accurate prints. It is validated for Formlabs' full dental resin library including surgical guides, denture bases, denture teeth, splints, models, and temporary crowns. The Form 4B pairs with the Form Wash and Form Cure for streamlined post-processing. Its open material validation program also allows use with select third-party resins.

Question 64

What is the difference between SprintRay Pro 55S and Pro 95S?

Accepted Answer

The SprintRay Pro 55S is designed for general dental lab use with a 55-micron XY resolution and a build volume suited for most dental applications including models, surgical guides, and denture components. The Pro 95S is a high-throughput production printer with a larger build volume, allowing labs to print more parts per batch. Both work with SprintRay's validated material ecosystem and the ProWash S and ProCure 2 post-processing stations. Choose the 55S for versatility and the 95S for high-volume production labs.

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