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3D Printing Occlusal Splints with Formlabs SLA 3D Printers

This application guide demonstrates each step for making 3D printed occlusal splints on Formlabs SLA 3D printers.

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Table of contents

  1. Scan
  2. Design
  3. Print
  4. Post-Process
  5. Care Instructions

1. Scan

Dental design software requires a digital impression of the patient’s anatomy in order to design a splint or occlusal guard. To acquire this data, scan the patient directly with a 3D intraoral scanner or scan a physical impression or a poured model with a desktop 3D scanner.

2. Design

There are several dental software options for digitally designing occlusal splints. In this application guide, we will be outlining parameters for 3Shape Dental System and ExoCAD. You can download Formlabs material libraries for 3Shape here or get Formlabs exocad material presets from exocad’s dental share platform. There are also outsourced dental CAD providers where you can send a digitized impression for creating the design.
Please check the appropriate manufacturing guide for material-specific construction requirements such as minimum occlusal surface thickness and minimum wall thickness. 
Dental LT Clear (V2): Offset from 0.05 to 0.10 mm (depending on the desired snugness and case design, the smaller the value the tighter the fit) Dental LT Comfort: Offset from 0.01 to -0.03 mm (depending on the desired snugness and case design, the smaller the value the tighter the fit)

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