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  • 3D Printing in Prosthodontics: Additive Manufacturing Technology

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    Riya Kv
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    1. 3D printing offers advantages over traditional CAD/CAM fabrication of dental restorations by allowing single-visit production and less wastage compared to subtractive methods. 2. The main types of 3D printing include stereolithography, digital light processing, fused deposition modeling, binder jetting, selective laser sintering, and selective laser melting. 3. These techniques work by building objects layer-by-layer from digital files through processes like photopolymerization, powder fusion, or material deposition and can produce dental restorations, models, and surgical guides.

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    INTRODUCTION.

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    1. 3D printing offers advantages over traditional CAD/CAM fabrication of dental restorations by allowing single-visit production and less wastage compared to subtractive methods. 2. The main types of 3D printing include stereolithography, digital light processing, fused deposition modeling, binder jetting, selective laser sintering, and selective laser melting. 3. These techniques work by building objects layer-by-layer from digital files through processes like photopolymerization, powder fusion, or material deposition and can produce dental restorations, models, and surgical guides.

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    76 views6 pages

    3D Printing in Prosthodontics: Additive Manufacturing Technology

    Uploaded by

    Riya Kv
    1. 3D printing offers advantages over traditional CAD/CAM fabrication of dental restorations by allowing single-visit production and less wastage compared to subtractive methods. 2. The main types of 3D printing include stereolithography, digital light processing, fused deposition modeling, binder jetting, selective laser sintering, and selective laser melting. 3. These techniques work by building objects layer-by-layer from digital files through processes like photopolymerization, powder fusion, or material deposition and can produce dental restorations, models, and surgical guides.

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    of 6

    3D PRINTING IN PROSTHODONTICS

    INTRODUCTION

    Technological developments have made significant impact and contributions to


    the field of dentistry.

    Right from adaptation of lost wax technique in early 20th century for the
    fabrication of crowns and bridge to the recent influence of computer aided
    design and machining (CAD CAM) technology on digitisation of restorations.
    Traditional fabrication of inlays, onlays and crowns uses a multistage process
    which involves an indirect technique of an impression followed by laboratory
    processing of the restoration. This procedure involves several steps which
    increases the possibility of errors in marginal accuracy, time consumed by the
    patient as well as the doctor and the treatment costs. As in many other
    industries, production stages are increasingly becoming automated in dental
    technology.

    Principles of subtractive manufacturing have been majorly used by both lost


    wax technique and CAD CAM technology .

    CAD/CAM systems allow for the production of indirect restorations in a single


    visit. These systems use an optical camera to take a virtual impression by
    creating a three dimensional image which is forwarded to a software program.
    This impression results in a virtual cast on which the restoration is designed.
    The software then controls a milling process that uses prefabricated blocks of
    restorative material, either ceramic reinforced composite or all-ceramic
    material, to produce the restoration. The end result is chair side production of
    the restoration.

    However, subtractive manufacturing brings with it disadvantage of increased


    wastage with removal of excess material and inability of mass production.

    ADDITIVE MANUFACTURING TECHNOLOGY

    Additive manufacturing on the other hand opens up new avenues for


    production of dental restorations. Additive manufacturing according to the
    American Society for Testing and Materials (ASTM) is the process of joining
    materials to make objects from 3D model data, usually layer upon layer, as
    opposed to subtractive manufacturing methodologies. The process of additive
    manufacturing works on the principle of taking a 3D computer file and creating
    a series of cross sectional slices. Each slice is printed one on top of the other to
    create the 3 dimensional object with an advantage of minimal wastage. Today
    additive manufacturing can apply for product life cycle from prototyping to full
    scale manufacturing. It can be promising as it offers less time, more productive
    in terms of mass production thus overall reducing cost being used more in
    aerospace and automobile to develop complex geometries.

    3D PRINTING OVER CAD CAM TECHNOLOGY

    Subtractive methods such as CAD CAM has some limitations in relation with 3
    D printing.

    1. Large amount of raw material is wasted because of unused portions of the


    mono-blocks which are discarded after milling and recycling of the excess
    ceramic is also not feasible.

    2. Milling tools are prone to heavy abrasion and wear which shortens their
    cycling time.

    3. Due to brittle nature of ceramic microscopic cracks can be introduced during


    the process of machining.

    THE MAIN COMPONENTS OF A 3D PRINTER

     3D Printer Frame: Holds the machine together


     3D Printer Head movement mechanics: moves relative to the print bed in
    all directions
     3D Printer Head: Nozzle that deposits filament or applies colors and
    liquid binder
     3D Build Platform or Build Bed: The part of the printer where the object
    is printed
     3D Printer Stepper Motors (at least 4): Used for precise positioning and
    speed control
     3D Printer Electronics: Used to drive motors, heat the extruder and much
    more
     3D Printer Firmware: Permanent software used to control every aspect of
    a 3D printer
     3D Printer Software: Not part of the actual printer but still needed for the
    printing process
    Here are the nine 3D printing types:

    1. Stereolithography (SLA)
    2. Digital Light Processing (DLP)
    3. Fused deposition Modeling (FDM)
    4. Selective Laser Sintering (SLS)
    5. Selective Laser Melting (SLM)
    6. Electronic Beam Melting (EBM)
    7. Laminated Object Manufacturing (LOM)
    8. Binder Jetting (BJ)
    9. Material Jetting (MJ)

    1.STEREOLITHOGRAPHY (SLA) TECHNOLOGY


    Stereo lithography was introduced in 1980 by Charles Hull.

    SLA is a fast prototyping process. This is a 3D printing process that’s popular


    for its fine details and exactness. It works by converting liquid photopolymers
    into solid 3D objects, one layer at a time. SLA printing has become a favored
    economical choice for a wide variety of industries. Some of these include
    automotive, medical, aerospace, entertainment, and also to create various
    consumer products.It is used to make implant surgical guides because of high
    mechan ical strength, obturators, surgical stents, duplication of prosthesis and
    burn stents.

    2) DIGITAL LIGHT PROCESSING (DLP) TECHNOLOGY


    DLP is the oldest of the 3D printing technologies, created by  Larry
    Hornbeck back in 1987. It’s similar to SLA , given that it also works with
    photopolymers. Compared to SLA 3D printing, DLP achieves quicker print
    times because it exposes entire layers at once. DLP printing technology is that it
    is robust and produces high resolution models every time. It’s also economical
    with the ability to use cheaper materials for even complex and detailed objects.

    3. FUSED DEPOSITION MODELLING

    Developed by Schott Crump

    It is used mostly for modelling and prototyping applications. This technology


    works on the principle of extruding a thermoplastic filament material through a
    heated nozzle and the material hardens immediately after extrusion . Materials
    such as acrylonitrile butyro styrene ABS, polycarbonates and poly sulfones are
    used.

    4.BINDER JETTING TECHNOLOGY

    The Massachusetts Institute of Technology (MIT) first invented Binder Jetting


    3D printing.

    Also known as:

     Powder bed printing


     Inkjet 3D printing
     Drop-on-powder
     Binder jetting .

    Binder jetting is a 3D printing process that uses two types of materials to build
    objects: a powder-based material (usually gypsum) and a bonding agent. As the
    name suggests, the “bonding” agent acts as a strong adhesive to attach (bond)
    the powder layers together. The printer nozzles extrude the binder in liquid form
    similar to a regular 2D inkjet printer. After completing each layer, the build
    plate lowers slightly to allow for the next one. This process repeats until the
    object reaches its required height.

    5. SELECTIVE LASER SINTERING (SLS) TECHNOLOGY


     Dr. Carl Deckard developed SLS technology in the mid-1980s.

    It’s a 3D printing technique that uses high power CO2 lasers to fuse particles
    together. The laser sinters powdered metal materials .It’s a process that repeats
    one layer at a time until it reaches the object’s height. SLS is quite similar to
    SLA technology with regards to speed and quality.

    Selective laser sintering is used in fabrication of anatomical study models,


    cutting and drilling guides, dental models, and also for engineering/design
    prototypes. Advantages are ease of autoclavability of the materials used, full
    mechanical functionality of the printed objects, lower cost materials if used in
    large volume. Disadvantages are powders are messy with increased inhalation
    risk, technology is expensive, and significant climatic conditions such as
    compressed air are required.

    6.SELECTIVE LASER MELTING (SLM) TECHNOLOGY

    Invented in 1995.Like SLA , SLM also uses a high-powered laser beam to form
    3D parts. During the printing process, the laser beam melts and fuses various
    metallic powders together.

    As the laser beam hits a thin layer of the material, it selectively joins or welds
    the particles together. After one complete print cycle, the printer adds a new
    layer of powered material to the previous one. The main difference between
    SLM and SLS is that SLM completely melts the powder, whereas SLS only
    partly melts it (sinters). In general, SLM end products tend to be stronger as
    they have fewer or no voids.

     7.ELECTRON BEAM MELTING (EBM) TECHNOLOGY


    A Swedish company ,Arcam AB founded EBM in 1997. This is a 3D printing
    technology similar to SLM , in that it uses a powder bed fusion technique. The
    difference between the two is the power source. The SLM approach above uses
    high-powered laser in a chamber of noble, or inert gas. EBM, on the other hand,
    uses a powerful electron beam in a vacuum. EBM’s main use is to 3D print
    metal parts. EBM also produces parts that are incredibly strong and dense in
    their makeup.The features include:

     It doesn’t need extra auxiliary equipment for the 3D printing process


     It has increased efficiency using raw materials
     Lessens lead times resulting in parts getting to market faster
     Can create fully functional, durable parts on demand for wide-ranging
    industries.

    8) Laminated Object Manufacturing (LOM) Technology


    LOM is a rapid prototyping system that works by fusing or laminating layers of
    plastic or paper using both heat and pressure. A computer-controlled blade or
    laser cuts the object to the desired shape. Once each printed layer is complete,
    the platform moves down by about 1/16th of an inch, ready for the next layer.
    The printer then pulls a new sheet of material across the substrate where it’s
    adhered by a heated roller. This basic process continues over and over until the
    3D part is complete.

    9) MATERIAL JETTING (MJ) POLYJET AND WAX CASTING


    TECHNOLOGY
    also known as wax casting.
    .In fact, up until recent times it’s been more of a technique than an actual
    printing process. It’s something jewelers have used for centuries. Wax casting
    has been a traditional process where the user produces high-quality,
    customizable jewelry.  Today, MJ 3D printers produce high-resolution parts,
    mainly for the dental and Jewelry industries,

    Once the 3D model (CAD file) is uploaded to the printer, the printer adds
    molten (heated) wax to the aluminum build platform in controlled layers. It
    achieves this using nozzles that sweep evenly across the build area. As soon as
    the heated material lands on the build plate it begins to cool down and solidify
    (UV light helps to cure the layers). As the 3D part builds up, a gel-like material
    helps to support the printing process of more complex geometries. Like all
    support materials in 3D printing, it’s easy to remove it afterward, either by hand
    or by using powerful water jets. Once the part is complete,no further post-curing
    is necessary.

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