Dental 3D Printing: Guide to Technologies and Workflow

3D printing has transformed the dental sector, enabling the rapid and precise production of models for aligners, dentures, crowns & bridges, custom trays, orthodontics, and implantology. This technology offers a level of customization and quality previously unattainable with traditional methods. However, not all printing technologies are equal: depending on your priorities—precision, volume, cost, or durability—the choice of technology will directly impact results. A thoughtful strategy, from technology selection to workflow organization, is therefore essential to maximize clinical and industrial success.

What Are the Main Dental 3D Printing Technologies?

Two technologies dominate the dental market: Digital Light Processing (DLP), and Liquid Crystal Display (LCD). All rely on photopolymerization, but differ in their light source and projection method, which influences precision, speed, and part durability.

Digital Light Processing (DLP) – Optimal Precision and Productivity

Advantages:

High precision and dimensional fidelity
Batch production possible
Surface finish suitable for direct clinical use

Limitations:

Higher initial cost than LCD
Requires investment in a dedicated printer

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DLP uses a digital projector to solidify an entire layer of photopolymer resin in a single projection. This pixel-based resolution delivers fine detail, essential for faithfully reproducing the complex geometries of orthodontic models and custom prostheses.

Prodways’ proprietary MOVINGLight® technology takes DLP even further. The moving projector offers a print surface of up to 300 × 445 mm with a resolution of 42 µm per pixel (600 DPI), while the top-down system reduces peeling forces and vat wear, enabling batch production of up to 72 denture bases or 55 aligner models per cycle.

DLP represents the ideal compromise between speed, precision, and reliability, making it the most suitable technology for demanding dental laboratories and practices.

Liquid Crystal Display (LCD) – Speed and Accessibility

LCD relies on a liquid crystal screen at the bottom of the vat that masks UV light according to the shape of each layer. This method allows rapid printing and an attractive initial cost, appealing to small practices and laboratories.

However, the screen degrades with prolonged UV exposure, requiring regular replacement. Precision, while sufficient for some study models or trays, remains lower than DLP or SLA.

Advantages:

Low initial cost
High printing speed
Simple to implement for basic parts

Limitations:

Lower precision for complex applications
Limited screen durability
Less suitable for batch production

Comparative Evaluation of Dental 3D Printing Technologies

Technology	Model Fidelity (Trueness)	Reproducibility (Precision)	Key Advantages	Limitations	Ideal Applications
DLP	★★★★☆ (very high)	★★★★☆ (consistent)	High precision, speed, batch production, good durability	Higher initial cost than LCD	Aligner Models Denture Crown & Bridge Models Custom Tray Orthodontic Models Implantology Models
LCD	★★★☆☆ (adequate)	★★★☆☆ (variable)	Attractive purchase price, fast printing	Screen wears out, lower precision	Simple models, temporary devices, rapid prototypes

What You’ll Learn in Our E-book

Our guide, written by Prodways Machines experts, walks you through every step of an automated dental production workflow :

How to Structure an Efficient Dental 3D Printing Workflow

A well-designed production workflow is essential to ensure precise prints, reduce hidden costs, and optimize equipment lifespan. The key steps to build an efficient process are:

Choosing the Right Equipment

Price should not be the only criterion. A printer specifically designed for the dental field ensures better compatibility with materials and consistent results. Choosing an open system printer allows the use of different resins according to needs, offering more flexibility and a better long-term return on investment.

Optimizing CAD Parameters

Each resin and printer has ideal parameters, and adjusting part orientation, layer thickness, and nesting helps achieve the right balance between quality, speed, and yield. A well-thought initial configuration reduces post-processing and limits the risk of defects.

Starting Gradually

To master the technology and limit costly errors, it is recommended to start with simple applications such as study models or aligners. Once the basics are acquired, one can progressively move to more complex items: fixed prostheses, surgical guides, or even implants.

Integrating a Complete Workflow

Overall efficiency does not rely solely on printing but on the entire digital chain. An optimized workflow includes:

Intraoral scanning or model
CAD and/or AI design
Preparation and nesting
Printing and post-processing
Quality control
Packaging and shipping

This integrated approach ensures reliable production, reduces waste, improves traceability, and contributes to more sustainable manufacturing.

To truly optimize your workflow and exploit the full potential of these technologies, it is essential to go beyond simple technical comparison and integrate solutions adapted to your specific needs.

Download the Prodways ebook now to discover in detail:

The technical advantages of each 3D technology
Practical advice to structure an efficient printing workflow
Concrete case studies in dentistry

This guide will allow you to make informed decisions and maximize the quality, productivity, and profitability of your dental 3D printing projects.

FAQ – 3D Printing in Dentistry

What is the best 3D printer for dental models?

The choice depends on lab or office priorities. DLP is generally recommended for its balance of precision, speed, and volume. Prodways’ MOVINGLight® technology enables batch printing while maintaining 42 µm resolution. LCD remains an economical option for simpler models where maximum precision is not required.

How is 3D printing used in dentistry?

3D printing allows the production of orthodontic models, crowns, bridges, surgical guides, aligners, and complete prostheses. It facilitates rapid prototyping, and precise customization of patient anatomy The typical process includes scanning, CAD design, printing, post-processing, and finishing, ensuring a consistent result adapted to each patient.

How much does it cost to print a dental model?

The cost depends on printer technology, resin type, and production volume. LCD printers offer a lower initial cost but require regular screen replacement, while DLP and SLA printers, more expensive to purchase, ensure better precision and long-term durability. Dental resins generally cost between €50 and €150 per liter. Investing in high-precision printers like DLP often reduces material waste and rework, generating savings in the long term.

What are the disadvantages of 3D printing in dentistry?

Despite its many advantages, 3D printing has some limitations:

LCD printers degrade over time under UV exposure, which can affect their reliability.
DLP printers, although very precise, require rigorous calibration and optimal workflow management to ensure consistent results.

[Article] Which 3D Printer to Choose for Precise and Reliable Dental Models?