As a dentist managing a general practice, efficiency is crucial since shorter chair time translates to lower operational costs and enhanced patient satisfaction. Dr. Christopher Baer, DMD, of Baer Dental, a general dental practice based in Lone Tree, Colorado, utilizes 3D printing technology to produce models for retainers, custom whitening trays, wax-ups, temporary and permanent restorations, surgical guides, and occlusal splints.
Being an early adopter of 3D printing, Dr. Baer employs printers from various manufacturers. However, he was immediately impressed with Formlabs’ new Form 4B. “It was incredibly fast. We can now print eight models in the same time it previously took to print one, and the quality is excellent,†he says. This speed has made single-visit dentistry a reality, allowing for appliance fabrication before the patient leaves the practice.
“I started with a Formlabs printer—the Form 2—and have been incorporating this technology into my practice for quite some time,†explains Dr. Baer. Recognizing the benefits early on, he embraced the technology and aimed to advance its use. “I believe it has improved both our treatment workflows and outcomes.â€
Dr. Baer highlights that with Form 4B, “We can essentially print a splint the same day for a patient by the time they finish their cleaning visit, which is ideal.†Delivering an appliance chairside involves not just printing but also post-processing. Therefore, the entire workflow from design to finished appliance must be considered. Other printers require significant time for polishing, but with Form 4B, “the outer surface is pristine, so after printing an appliance, a light polish is all that’s needed.â€
One memorable instance involved a patient with a broken retainer. While the patient went to grab a cup of coffee, Dr. Baer printed a new model. Upon returning, the patient received a fresh set of retainers and was delighted. “He was leaving town for a few weeks, so he was very grateful we could do that,†recalls Dr. Baer.
The Form 4B combines blazing speed with unmatched accuracy, making it a game-changer in dental 3D printing. Explore the latest innovations in our webinar to see how Form 4B is revolutionizing dental practices.
Dr. Baer frequently uses the Form 4B to print appliances for multiple applications, easily switching between resin cartridges and tanks for different materials. Occlusal splints are among the most commonly printed appliances. “Patients truly appreciate our ability to fabricate a secondary appliance at minimal cost,†notes Dr. Baer. Many patients travel, so they have a primary appliance at home and a travel version as a backup. If one breaks, a reprint can be ready before they walk into the office.
Retainers and whitening tray models are also frequently printed. “Using the fast settings for Fast Arches, we can print a model in about 10 minutes, and within 15 to 20 minutes, we have ready-to-use whitening trays for the patient.â€
Occlusal splints and retainer/whitening tray models are often the highest-volume appliances in a general practice. Simple workflows for 3D printing make them excellent applications for those transitioning to digital dentistry. Additionally, Dr. Baer prints surgical guides and temporary and permanent restorations. For full-arch cases, he successfully uses Premium Teeth Resin, a nano-ceramic-filled Class II biocompatible material with enhanced aesthetics.
Dr. Baer finds that appliances printed on Form 4B are smooth and accurate. “The level of detail for Form 4B, especially when doing wax-ups, ensures there’s no transference of fine lines to the final appliance. This results in better, clearer appliances.†For temporaries, this means “no lines that patients typically feel.â€
Patients at Baer Dental find the surface quality and accuracy of models produced using Form 4B more appealing. “It’s like the difference between old-school television and HD television,†says Dr. Baer.
Form 4B offers a surface accuracy of 95% ±50 μm, consistent across the build platform. Whether printing one model or nine, they all maintain a high degree of accuracy.
Resin 3D printers print layer by layer, and many are known for showing distinct layer lines on finished prints. These lines can transfer to thermoformed appliances or require additional post-processing to achieve the desired finish. Additionally, if supports are needed, extra time for polishing may be required.
“The thing that surprises me most is the quality. Given the speed, you’d expect a compromise in quality, but that’s definitely not the case. The models actually look better and are faster,†says Dr. Baer.
Form 4B’s resin tank is rated to print 75,000+ layers with any Formlabs material. Material costs are also low, making it easy to try new applications without a large investment. Print failures, maintenance, and troubleshooting waste valuable time and resources, so predictability and durability are key. Dr. Baer was impressed by the Form 4B’s overall quality from the moment he opened the box. Basic maintenance is essential for any 3D printer. When maintenance is needed, the intuitive user interface provides clear instructions. Cleaning the resin tank is straightforward, saving time compared to scraping and cleaning the entire tank.
Ultimately, Dr. Baer concludes, “From printing models to printing a night guard, you’re going to save a considerable amount of time with Form 4B compared to other printers on the market.â€
Learn more about the Form 4B or talk to a dental 3D printing expert to find the solution that best fits your practice.
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