Guide for Using Shape X for 3D Printing Full Dentures.

The manufacturing of traditional dentures is a complex skill that requires extensive training, and dental labs are facing challenges in finding technicians with the necessary expertise to produce them.

Digital Dentures offer a solution to this problem by providing dental laboratories with an efficient and cost-effective 3D printed denture option. With the use of Class II long-term biocompatible Denture Base Resin and Denture Teeth Resin, dental professionals can consistently produce accurate and reliable 3D printed full dentures.

While the manufacturing process for digital dentures differs from the traditional workflow, the chairside process remains quite similar. This application guide provides detailed information on the key considerations and steps involved in transitioning from a digitized patient model to a 3D printed full denture.

Required Hardware

• Shape X RP
• Shape X 3D Printer
• Shape X Wash/Dry
• Shape X Cure

• 3rd Party Dental Lab scanner for dental models or impression.
• 3rd Party Intraoral scanner for direct patient scan.

Required Software

• Shape X CAM

• 3rd Party Dental CAD software for designing restoration.

Required Materials

• Shape X Denture Base Resin.
• Shape X Denture Teeth Resin.

• Isopropyl alcohol (IPA) ≥99% .
• Polishing or glazing equipment and materials

In order to design a dental prosthetic using dental CAD software, it is necessary to obtain a digital representation of the patient's anatomy. This can be accomplished by either directly scanning the patient's mouth using a 3D intraoral scanner or by scanning a physical impression or poured model using a desktop 3D scanner.

Please adhere to the instructions provided by your denture design software in order to create the design for your denture.

Most dental design software typically generates a manufacturing file in the .stl format. To proceed, you need to find this file and transfer it to Shape X 3D Printer.

* Before Press "Print" button:

> Please ensure that the black screw of the build platform and the set of two screws that hold the resin container are securely tightened.

> Carefully inspect both the build platform and the resin container film to ensure there is no cured resin present.

> Ensure that the resin temperature falls within the recommended range of 25 to 35°C. Preheat the resin if necessary and mix it thoroughly with Shape X RP. Before use, clean the resin container with a filtration paper if it has been previously used. Additionally, ensure that the resin is not expired and that the quantity in the container is above the indicated minimum level.

4.1 Part Removal

To remove the printed parts from the build platform, utilize a scraping tool positioned beneath the part raft. By rotating the tool, gently separate the parts from the platform.

4.2 Washing

In a well-ventilated area and while wearing appropriate protective masks and gloves, submerge the printed parts in an isopropyl alcohol (IPA, ≥99%) solution within the Shape X Wash/Dry apparatus. Allow the parts to undergo a 3-minute washing cycle.

or submerge the printed parts in an isopropyl alcohol (IPA, ≥99%) solution within a black box. Allow the parts to undergo a 6-minute washing cycle.

4.2 Drying

Utilize compressed air to aid in the drying process of the parts, facilitating a quick inspection of unwashed resin remaining after using Shape X Wash/Dry machine.

4.3 Curing

1> While keeping the raft and supports intact, position the printed parts in the Shape X Cure device with the raft side facing downwards. Proceed to post-cure the parts for a duration of 2 minutes.

2> Remove Support structure and raft with cutting disc.

3> Clean Parts from white powder with IPA, then compressed air.

4> Position the printed parts in the Shape X Cure device. Proceed to post-cure the parts for a duration of 2 minutes.

4.4 Assembly

To assess the fit of the denture, place the teeth into the denture base. If there are any obstructions preventing proper alignment, trim the teeth and base accordingly using a hand tool. Utilize uncured denture resin base to securely bond the teeth to the denture base. Then, proceed to cure the entire assembly with Shape X cure for a duration of 5 minutes.

4.5 Finishing

Similar to the process for a traditional denture, proceed with polishing the denture using a rag wheel on a lathe with pumice at low speeds. Conclude the polishing process at high speeds, employing a polishing compound for optimal finishing.

Rinse the finished denture thoroughly with room temperature water. To ensure sterilization, utilize a steam cleaning process. Now, your denture is prepared and ready for delivery.