How to Choose the Right Dental 3D Printer for Your Office
(2025 Guide for Practices)
There are two ways to look at dental 3D printing in dentistry: either it’s the future, or it’s the present. The truth is that chairside 3D printing is no longer a distant innovation but an essential integration into modern dental practice.
Intraoral scanners are a gateway into the field of digital dentistry and even then, only 53% of practices have an intraoral scanner in their office (1). When it comes to dental 3D printing, an ACE Panel report featuring data from ADA member dentist found that 17% of dentists currently use a 3D printer, and of them, 67% have been using it for less than two years. (2) With digital impressions becoming standard, the ability to design and produce 3D printed dental applications, including dental splints, restorations, models and more in-house, enhances precision, efficiency, and overall patient care. The learning curve associated with 3D printing is steadily becoming more manageable, making adoption increasingly accessible for dental offices.
The purpose of this article is to help dentists, dental assistants, in house dental lab technicians and office managers navigate the complex world of in-house 3D printing and choose the ideal dental 3D printer for their specific clinical and operational needs.
Evaluate the needs and justify the investment. What do your daily clinical workflows look like?
Before selecting a dental 3D printer, it’s essential to assess the specific needs of your dental practice. Start by evaluating your clinical workflows. What does your day to day look like?
Are you regularly delivering surgical guides, splints, dentures, or temps? The right printer should fit your workflow and not the other way around. The goal is to make life easier for you, your staff and your patients.
Why Start 3D Printing in Your Dental Office?
- Reduced Lab Costs: Eliminate outsourcing fees for common applications
- Same-Day Dentistry: Print restoratives, splints, and guides chairside
- Patient Satisfaction: Faster treatment times and better fitting appliances
- Practice Efficiency: Streamlined workflows and reduced appointments
- Future-Proofing: Stay competitive with advancing dental technology
Understanding the Different 3D Printing Technologies in Dentistry
Dental 3D printing describes a broad range of additive manufacturing techniques. Dentistry primarily uses resin-based 3D printing due to its superior accuracy and material properties. While metal and FDM printing exist, resin-based systems offer the highest resolution and ideal material properties needed for intraoral applications.
The three common resin-based dental 3D printing technologies (3,4)
- SLA (Stereolithography): Uses a laser to cure resin with high accuracy.
- DLP (Digital Light Processing): Utilizes a projector to cure entire layers at once, enabling faster speeds.
- LCD (Liquid Crystal Display): Uses an LCD screen and UV light to cure resin, offering affordability with competitive precision
These technologies use a type of additive manufacturing process known as vat photopolymerization. A vat (resin tank or reservoir) contains the liquid photopolymer resin which is selectively cured layer by layer depending on the light source. The bottom of the vats can be manufactured in different materials such as FEP, nFEP, PTFE or Glass (5). It is not important to understand the terminology but rather the dentist needs to be aware of the different types.
Light source in 3D printing
3D printers use light as a source of energy to cure. Over time the quality of this light source can degrade and directly affect the quality of prints. An investing clinician should think about how this issue is addressed by the printer. LCD printers are more susceptible to high intensity light that degrade LCD screen and will eventually need to replace the screen.
DLP printers on the other hand are capable of a much wider light intensity band but need calibration. A mechanism that measures and calibrates the light source is immensely important in these printers to ensure consistency. At some stage, a DLP light source will also require replacement although its life cycle is significantly longer. (6)
The 3D Printer Checklist: What Really Matters?
| What do Dentists want in 3D printers? | What to look for? |
|---|---|
| Prints that succeed without failure | Reliability |
| Accurate prints with smooth surface finish | Resolution |
| Fast print times | Speed |
| Compatibility with various resins | Open System |
| Easy setup and minimal training | Plug and Play |
| Minimal breakdowns and maintenance | Robustness |
| Simple to operate and handoff | Delegation |
| Intuitive, user-friendly software | UI/UX |
| Complete validated workflows | Full Ecosystem |
| Support and training | Customer Service |
As we go through this article we will discover if the Rapid Shape PRO 20 ecosystem satisfies the above criteria.
How does 3D printing resolution impact my printed dental application?
In 3D printing there are a couple of terms and measurements that are often used interchangeably but are separate parameters impacting the overall quality and fit of each dental 3D print and are indicators for the reliability of a 3D printing solution.
For this article, we will focus on two technical parameters:
- XY Resolution: DLP printers work with projectors. Projectors cast light with a specific pixel size. The rule of thumb here is that the smaller the pixel, the better the resolution and overall, the smoother the surface of the print job. When the pixel size is too large, then dental applications, for example an analog, will not fit an implant model or a 3D printed crown will not fit the prepared tooth.
Most dental DLP printers today range within 25 to 50 microns, which is ideal for printing dental applications requiring intraoral fit.
A high XY resolution makes up only one component of “Accuracy”, with accuracy in 3D printing meaning to be able to reproduce the same print quality over repeated test.
- Z-axis resolution: Also referred to as layer thickness or the minimum height of each printed layer. The higher the print layer thickness, the more visible are layer lines, potentially impacting the fit and feel of a dental application. Most dental printers offer layer resolutions between 50 and 150 microns.
| Layer Thickness | Recommended Use |
|---|---|
| Thin layers (25–50 µm) | Good for die models, crowns, bridges, and veneers, advanced surgical guides. |
| Thicker layers (75–100 µm) | Suitable for models, basic surgical guides, splints, denture bases or other less detail-sensitive appliances. |
| Thick layers (125–150 µm) | Suitable for study models or quick prototyping. |
A lower resolution setting results in a smoother surface quality and it may impact the fit for die and implant models. For dental technicians wanting to draw on the surface of models, a 50-micron layer thickness is recommended. However, lower resolution also increases print time. It is worth noting that not all resins can be printed on a thin layer thickness due to viscosity. Choosing a printer with adjustable layer thickness and being mindful with the choice of resin allows flexibility for different clinical tasks, optimizing both detail and efficiency as needed.
Speed and Efficiency in Dental 3D Printing
Every dental practice is busy, making speed and efficiency essential. In an office where same-day dentistry is practiced, printing speed can either make or break a workflow. However, speed must be carefully weighed against the desired fit and surface quality of dental a print. A faster 3D printer that sacrifices precision may lead to more remakes, adjustments, or chairside modifications.
As previously discussed, increasing layer thickness is a common approach to speed up printing, an approach many dental offices adopt to save time. However, if a printer offers high speed without compromising on layer thickness, that’s a feature worth serious consideration. Ultimately, the right 3D printer balances precision and performance.
| Resin Type | Avg Resin Use (mL) | Resin Cost (USD) | Print Time (hours)* | Labor/Post (USD) | Total Est. Cost (USD) | |
|---|---|---|---|---|---|---|
| Splint | Splint Resin | 18–25 mL | $9–$13 | ~1.5 hrs | $12 | $21–$27 |
| Surgical Guide | Surgical Guide | 8–12 mL | $5–$7 | ~1 hr | $9 | $14–$16 |
| Model | Model | 50–60 mL | $12–$15 | ~30 min. | $9 | $21–$24 |
| Crown | Permanent Crown | 1.5–2 mL | $7–$10 | ~15 – 30 min. | $6 (incl. polish) | $13–$16 |
| Bridge (3-unit) | Permanent Crown | 3.5–4.5 mL | $15–$18 | ~15 – 30 min. | $9 | $24–$27 |
| Full Arch Bridge | Permanent Crown | 10–12 mL | $36–$48 | ~30 min. | $12 | $48–$65 |
| Denture (Monolithic or Split) | Denture Base + Teeth Resin | 35–50 mL (base + teeth) | $18–$30 | ~2 hrs. | $15 | $33–$45 |
| Custom Tray | Tray Resin | 25–30 mL | $6–$9 | ~2 hrs | $6 | $12–$15 |
*Costs vary to a degree depending on cost of resin and post-processing labor
Dental Resin Compatibility and Software Integration
A chairside dental 3D printer is only as versatile as the materials it can process. For clinical use, especially inside the mouth, it’s important to use biocompatible, certified dental resins. These must meet especially strict standards for appliances that will reside long term in the oral environment like dental splints, dentures, and crowns.
Having a validated workflow is therefore extremely important and workflow validation does not depend on the resin alone.
The process of validation undergoes testing key factors such as: (8)
- Print orientation (Angulation and position)
- Layer resolution (25-150 micron)
- Light intensity (Intensity and Uniformity)
- Support structures (Design and Placement)
- Post processing (washing, drying, and curing)
These settings are customizable in the right hands, but most dentists do not have the time to tweak workflows. Most dentists simply want to load a resin, hit the print button, and get reliable results without the trial and error.
Thus, an important feature to consider is whether the printer supports validated materials. A complete validated workflow ensures that the resin, 3D printer, and post processing equipment have been tested together to deliver consistent results that are safe for patients.
Additionally, some 3D printing ecosystems incorporate RFID resin tracking, which automatically recognizes materials and applies the correct print parameters and relevant post processing guidelines. There is also RFID ID tracking for 3D printer VATs (resin tanks) depending on the relevant 3D printing ecosystem. These not only improve reliability but also minimize human error. RFID integration can introduce additional ongoing costs, and this is something to consider.
Open vs Closed 3D Printing Systems
Cost is certainly a big factor when it comes to becoming an adopter of new technology. Certain dental 3D printing systems lock users into proprietary resins, while others offer open material platforms. Most dentists prefer to have flexibility. A closed system limits your ability to explore new and innovative dental resins that are currently available or those that may emerge in the near future.
CAD Software Integration in Digital Dentistry Workflows
Equally important to material compatibility is how well the 3D printer integrates with designs completed in CAD software such as Exocad or 3Shape. Seamless integration means less time spent troubleshooting file exports or adjusting for format inconsistencies. An ideal dental 3D printing system should allow direct ‘drag and drop’ import of designs into slicing software for easy printing.
AI-generated support structures have become essential for efficiency in modern dental 3D printing software. Print orientation and angulation directly affect accuracy, fit, and surface quality (7), especially for long-term intraoral appliances like dental splints, dental crowns, and denture bases.
Yes, training and education are important, but user interface is crucial for easy adoption and delegation. Reliable technical support can make a significant difference as well, especially during the onboarding phase but beyond that it needs to be plug and play with the occasional support ticket.
Ease of Use and Maintenance
A 3D printer should simplify your daily dental workflows, not complicate them. Intuitive interfaces, step by step pictorial prompts, touchscreen controls, all reduce the learning curve and allow staff to confidently manage print jobs with minimal oversight.
Maintenance is another key factor. Some printers require daily cleaning, resin tank replacements, or recalibration, while others are designed for extended use with minimal interruption. You want an ecosystem that is robust, reliable and simply built for production efficiency with minimal hands-on involvement.
Post-Processing Requirements for Dental Applications
Every printed dental appliance must go through a post-processing phase. These typically include a wash, dry and cure cycle. You want this to be automated as much as possible, and I cannot stress this enough. Post processing errors can significantly impact the success of a 3D print, either enhancing the final outcome or compromising it entirely.
Effective systems will have validated, automated wash and cure units that ensure resins are processed to meet clinical safety and strength standards. Manual wash and cure cycles simple lead to error time after time. Integrating wash and cure workflows also ensure that you can easily delegate post processing, with no fear of a validated workflow being compromised.
As a rule of thumb, a two tank two step wash cycle is more efficient than a one tank wash system. Curing is however a different domain. The age-old question with printing: Cure with glycerin, nitrogen, vacuum, heat or a mixture? Well, it depends on who you ask and what you are printing but different systems incorporate different technologies. Systems that integrate one or more of these technologies definitely offer an advantage over others. An increasing number of new systems are especially integrating vacuum and nitrogen at the very least. Glycerin is of course, easily added in any workflow. Not all resins require heat to achieve ideal properties. Indeed, heat may be detrimental to some resins. It is also possible to add an additional cure unit to a printing ecosystem if heat is desired, as long as the primary ecosystem is itself validated for a heat sensitive resin.
Dental 3D Printer Costs: Upfront vs Ongoing Expenses
The upfront cost of a dental 3D printer can vary significantly depending on the build quality, technology type, and included features. Entry-level 3D printers may seem appealing but often lack the workflows, seamlessness or support necessary for clinical use. Premium dental 3D printers, while more expensive, tend to offer better performance with long term viability because of their robustness of construction.
Beyond the initial upfront cost, dentists must consider the ongoing costs which are often overlooked:
✔ Resin costs (per print and per indication)
✔ Cleaning Solvents
✔ Need for replacement
✔ FEP/nFEP Film Replacement
✔ Vat/Reservoir replacement
✔ Software Licenses / Updates
✔ Maintenance & Repairs
All of these contribute to the total cost of ownership over a long-term period.
Digital Dentistry’s Return on investment
A well-chosen 3D printer can offer a strong ROI by reducing lab fees, enabling same-day dentistry with quick turnaround times, and production and post processing efficiency.
Here are some such examples to consider:
- In-house production of surgical guides or splints eliminates outsourcing lab delays and costs.
- Same-day temporaries reduce the need for multiple appointments and allow phased progression to definitive restorations.
- Same-day immediate dentures are so easy to fabricate and cost effective with a 3D printer.
- Same-day immediate implant restorations in immediate loading or in the aesthetic zone
- Same-day splints or deprogrammers are also very achievable
It is important to remember that with milling, same-day dentistry often stops at crowns. But with dental 3D printing, same-day possibilities extend to multiple applications. The biggest return on investment is indirectly through clinical efficiency, chair-time reduction and patient satisfaction improvement.
Final Recommendations: Choosing the Right Dental 3D Printer
Choosing the right 3D printer involves more than just the initial costs. Here are key takeaways when making your decision:
- Look for validated dentals materials with strong regulatory backing and proven biocompatibility.
- Prioritize dental printers that offer open, flexible workflows and integrate with your preferred CAD software.
- Consider total cost of ownership, not just initial purchase price.
- Choose a dental printing system that can scale with your practice and adapt to future advancements.
As 3D printing becomes an integral part of modern dentistry, the decision to adopt printing and the choice of a system is increasingly strategic. With the right technology and support, dental practices can unlock the full potential of 3D printing, positioning themselves at the forefront of the profession.
Scan to Print to Delivery: Dental 3D Printing Steps for Beginners
| Process | Key Details |
|---|---|
| Design | CAD software used to design model, splint, guide, denture, crown, etc. |
| Export Design | Export the design as an STL file. |
| Slicing | Load STL into slicing software (e.g., RS Print Studio,Netfabb). |
| Printing | Send sliced file to printer (via USB or Wi-Fi or ethernet connection) and start print |
| Post-Processing | Wash in isopropyl alcohol or solvent to remove uncured resin. |
| Post-Curing | Use curing unit to fully polymerize the print under UV light. |
| Finishing & Polishing | Remove supports, finish and polish. |
| Stain and Glaze (optional) | Characterize if needed. |
| Delivery | Check fit, function and deliver. |
My Review of the Rapid Shape PRO 20 3D Printing Solution
When I first unboxed the Rapid Shape PRO 20, I’ll admit I was not sure what to expect. I’ve seen a lot of dental printers over the years, but this one immediately stood out. It had that rare combination of precision engineering and elegance. I remember thinking to myself, “Oh, this is certainly a level up”. The build quality felt premium, the interface was intuitive, and the entire setup gave off a sense of confidence as if it knew exactly what it was built for.
I have had literal plug-and-play 3D printers before, and I will admit that I was initially quite cautious about setting it up the correct way. There is a bit of setup on Day 1 with Light calibration, Wi-Fi connection, software configuration, and yes it may take a little time. But once it is dialled in, the PRO 20 just does the job efficiently. There is a quick calibration to run on a weekly basis, but it takes less than a minute, and that’s time well spent to keep a workhorse running. The support was always available during onboarding, but now with step by step on screen prompts, it is hardly required. From the very first experience of going through the workflow from print to wash to cure, it was clear that workflow validation is at the heart of the system. This printing system is a well-designed clinical workhorse. One that respected my time, reduced my stress, and delivered consistently accurate results without the usual trial and error. The PRO 20 didn’t just meet my expectations or exceed them, it subtly redefined them.
Sure, I read about the Force Feedback technology in theory, but I did not expect it to hit me in practice. Typically, when I send a print job, it’s “set to print, forget and come back later.” But with the PRO 20, I remember looking at it thinking, “Wait… that’s it? Already?”. It just gets the job done before you realize the print time has passed. The PRO 20 didn’t just save time, it gives it back without ever making me question the quality or the layer thickness. What is interesting is that the speed is so good that the printer confidently reduces layer thickness even for applications like models.
| What do Dentists want in 3D printers? | Why does this matter? | Rapid Shape PRO 20 |
|---|---|---|
| Prints that succeed without failure | Reliability | Built to perform in combination with 24/7 access to Customer Service |
| Prints that fit accurately | High Resolution | XY Accuracy +/- 34μm |
| Fast print times | Speed | 15 minute models (50 micron thickness) 8 splints in less than 90 minutes (50 micron thickness) with RS Turbo + Force feedback technology |
| Compatibility with various resins | Open System | 200 + validated materials |
| Easy setup and minimal training | Easy to Setup | Moderate effort with easy to follow on screen prompts |
| Minimal breakdowns and maintenance | Robust | Premium manufacturing with Durable Glass VAT (resin reservoir) |
| Simple to operate and delegate | Operational Handoff | End to end validated post processing workflow |
| Intuitive, user-friendly software | User Friendly Software | RS Print Studio/Netfabb |
| A complete, integrated ecosystem | Complete Ecosystem | Printer + 2 Stage wash + Curing unit (Vacuum with Nitrogen inlet) |
| Support and training | Reliable Customer Service | Online knowledge portal with plenty of support material. RS support direct to printer TeamViewer connection. |
The PRO 20 is not just another high speed resin printer it is a fully integrated digital printing system. It ticks all the boxes in a 3D printing Checklist for me.
Now that we have understood the fundamentals of 3D printing, let’s see how well the RapidShape PRO 20 ecosystem fits into a dental practice.
The first step to a successful print is the successful nesting with a slicing software. Rapid Shape offers two software alternatives: Autodesk Netfabb and RS Print Studio. For day-to-day clinical printing, Print Studio offers a drag and drop simplicity with few easy clicks which is perfect for dentists and assistants. For the advanced user or lab, Autodesk Netfabb is also supported. This industry standard software unlocks powerful mesh repair, nesting optimization, and advanced support generation features. It is ideal for those who want to scale and want control of their workflow.
Most of the PRO 20’s prints are performed at 50 microns, not because it has to, but because it can. While many 3D printers struggle to maintain speed at this resolution, the PRO 20 is engineered to handle this without compromising detail due to its patented Force Feedback Technology. This is further accelerated by their perforated build platform. Rapid Shape believes that accuracy should not be a tradeoff for speed, and that if a printer can consistently deliver 50-micron precision, why settle for less? – Achieve consistent results with prints that fit.
The PRO 20 has been validated for over 200 resins, offering extensive flexibility for resin choices. There are many resin companies coming up with new advanced resins and I personally want the freedom to adapt to new and upcoming resins and the open nature of the PRO 20 makes it easy to onboard new resins quickly right after they are validated.
The second step in 3D printing is the wash cycle after a successful print. Once a print is complete, it typically undergoes a cleaning process to remove any uncured resin. Rapid Shape has a two-step, two tank wash system followed by a drying cycle which is great. All of this is possible in one tank with just a click of a button without having to transfer the prints between multiple tanks. This means your prints come out of the RS WASH, dry and ready for curing, saving time and reducing handling. However, not all resins require the same washing protocol. For instance, ceramic filled hybrid resins do not undergo full alcohol immersion. Instead, they require a limited alcohol spray and dry. What I find particularly impressive is that Rapid Shape’s validated workflows for materials like BEGO TriniQ, and Rodin Titan exclude a traditional wash cycle altogether in their system. In contrast, Detax Freeprint Crown (ceramic filled hybrid resin) does include a wash cycle, as the manufacturer recommends a 1-minute rinse, which is also incorporated into the workflow.
The WASH is equipped with RFID on the alcohol bottles as well, controlling and ensuring that non-biocompatible and biocompatible resins are not washed with the same alcohol. If you wash models in your first round and then want to wash a splint print job, a warning will pop on the WASH display and inform you to exchange alcohol bottles. It is recommended to have multiple bottles available, and with low purchasing cost, it is an easy way to ensure print jobs are always processed correctly and patient safety is ensured.
This level of resin specific detail shows the importance of a validated workflow. It also brings security to staff delegation, with no fear of incorrect post processing.
The third step in the 3D printing workflow is curing, and this is where RS CURE truly stands out. Most dentists are familiar with the ongoing debate around nitrogen, vacuum, glycerin, or standard chamber light curing (each with its pros and cons). The level of versatility that this offers to a resin manufacturer to combine various process in the development of a validated curing workflow is powerful. What this translates into for the clinical user, is a combination of techniques that result in the most efficient curing process possible and an optimized cure for every resin to its full physical properties.
When it comes to finishing, Rapid Shape prints already have an excellent surface quality straight off the build platform. For most applications, post processing steps like staining or minor refinements are similar across printing ecosystems. However, when it comes to occlusal splints, Rapid Shape uses a Crystal Polish reservoir. The result? Glossy clear splints that only require minimal touch ups in support areas. This helps preserve the carefully designed occlusion in a long-term occlusal splint. There is no wear of this occlusion during aggressive finishing and polishing that is otherwise needed.
In short, the Rapid Shape PRO 20 does not just fit into your practice, it scales it. Whether you are a beginner looking for a plug and play printer or an expert wanting full control over your workflow, the PRO 20 offers an experience that can be as basic or advanced as the user demands. Whether you are chasing same day splints or same day dentures or same-appointment full-arch immediate provisionals, this printer is built to work as hard and fast as you. It is engineered to perform and will help you realize that not all 3D printers are built the same.
References
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