While much has been said about the impact of 3D printing on the dental industry as a whole, it’s within dental laboratories that the technology is having its most transformative and immediate effect. Beyond streamlining workflows, 3D printing is expanding what’s possible—from high-volume model production to the development of fully digital processes that meet growing clinical expectations.
A Shift in Daily Production: What Labs Are Printing Most
Today, dental labs are producing an average of 397 models per month, a figure that underscores just how central 3D printing has become. These models—used primarily for crowns, bridges, and aligners—far outnumber the volume of other applications like nightguards or surgical guides, which average closer to 80 to 100 units per month. According to the latest LMT Research, over 76% of labs now use 3D printing to fabricate models for crowns and bridges, while 70% produce aligner models digitally.
These numbers aren’t just statistics—they reflect a complete reorganization of dental lab priorities. As digital impressions become the standard in dental practices, labs have had to keep pace, adopting printing technologies that can process high-resolution scans with precision and speed.
From Traditional Tasks to Fully Digital Workflows
One of the greatest shifts 3D printing has brought to dental labs is the growing ability to operate within a fully digital workflow. In fact, 63% of surveyed labs identified this as one of the most valuable benefits of printing technology. Gone are the time-consuming steps of waxing, manual model pouring, or trimming stone dies. Digital files move directly from design to production, increasing both speed and reproducibility.
But the transition isn’t just technical—it’s strategic. Dental professionals now expect quicker turnarounds and consistent quality, and 3D printing enables labs to deliver on those expectations. Digital workflows also make communication between dentist and technician more transparent and traceable, improving collaboration on complex cases.
Serving Dentists Better: Meeting Demand Through Innovation
With 59% of labs reporting increased dentist demand for printed units and models, 3D printing isn’t a bonus feature—it’s a response to market pressure. Dentists increasingly rely on intraoral scanners to take precise digital impressions. As a result, labs must be equipped not only to receive these files, but to process them efficiently and at scale.
This digital compatibility is now a competitive differentiator. Labs that can deliver models, aligners, or surgical guides with minimal manual rework are more likely to retain demanding clients and expand their service offerings. The demand for printed splints, for example, continues to rise—especially among labs already producing high volumes of orthodontic appliances.
Material Innovation: From Models to Denture Bases
Alongside workflow changes, advances in printing materials are expanding the clinical relevance of 3D-printed prosthetics. New-generation resins like PLASTCure Absolute Aligner are designed specifically for high-throughput aligner production, offering ultra-smooth surfaces and eliminating the visible layering often seen in older technologies. This results in better thermoforming accuracy and improved patient comfort.
In parallel, materials like Provivic Denture Base are making it easier and faster to produce full dentures without sacrificing aesthetics or precision. With a naturally tinted finish and excellent dimensional stability, this resin reduces the need for post-processing and offers a viable alternative to traditional denture workflows—particularly appealing for labs facing labor shortages or looking to cut turnaround times.
3D printing, more Than Just a Tool, an asset for moderns dental labs
When evaluating the full production output across categories—models, splints, guides, and prosthetics—over 50% of total items in a modern dental lab are now at least partially produced using 3D printing. This statistic highlights more than just adoption; it signals a fundamental change in how labs operate day-to-day.
Rather than relying on a handful of technicians to complete each task by hand, many steps are now automated or digitized, from design validation to final finishing. That frees up valuable time for quality control, case planning, and communication with clinicians—areas where human expertise remains essential.
Where the Industry Is Headed
As CAD technologies continue to evolve and integrate with printing systems, we’re seeing the early stages of more advanced applications—such as direct printing of removable prosthetics. Ceramic printing for crowns and bridges isn’t quite ready for widespread use, but development is accelerating, and labs should be prepared for what’s next.
In the meantime, the focus remains on refining what’s already working: reducing costs, improving consistency, and maintaining clinical precision.
With new materials emerging and production speeds increasing, labs that invest in 3D printing today are better positioned for tomorrow’s market.
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Source : LMT Research Dept - 2024
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