1243 E Broadway Rd, Tempe AZ · (480) 449-09093433 E Ft Lowell Rd, Tucson AZ · (520) 795-7970
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PROCEDURE

3D-Printed Restoration

Dani Dental's 3D-printed restoration workflow runs on validated resin and polymer stacks that have been calibrated in-house since 2021. Provisionals, surgical guides, and full-arch temporaries exit our Arizona lab in as little as 24 hours after scan receipt.

  • Margins verified against your prescription
  • Pre-paid two-way shipping
  • Talk to the technician who built it
  • Full digital workflow

Every 3D-printed case at Dani Dental enters the same digital intake chain regardless of case type. Intraoral scan files (STL, OBJ, or PLY) or CBCT-derived DICOM exports land in our secure upload portal and are assigned to a named technician within two hours of receipt. That technician owns the file through print dispatch. No handoffs between anonymous CAD operators. We run two validated printers on the restoration floor: the Formlabs Form 4B for provisionals, splints, and diagnostic wax-up equivalents, and the SprintRay Pro 95 for surgical guide fabrication. Each material profile is dialed to the printer and re-validated quarterly. When Formlabs or SprintRay updates firmware, we re-run our marginal fit benchmarks before the update goes live on production machines. That discipline is why the sub-50-micron tolerance is reproducible, not a single-case anomaly. For full-arch temporaries on implant cases, the design phase is the longest part of the job. Our technicians work in exocad and cross-reference the treating clinician's occlusal scheme before a single layer prints. If the digital plan conflicts with the surgical guide or the CBCT anatomy, the technician calls the doctor's line directly. Not a ticket, not an email thread. A phone call, resolved same day. Post-print finishing follows a controlled protocol: support removal, isopropyl alcohol wash in a closed-loop IPA station, dual-cure light cycle timed to material spec, and a final occlusal check against the digital articulator. Every printed restoration ships with a one-page case summary that includes the print parameters, material lot number, and the technician's direct line. Surgical guides receive an additional fit-check step. We print a reference model from the same DICOM file and seat the guide on it before shipping. If the guide rocks or gaps beyond 0.1 mm at any sleeve site, it reprints. No exceptions, no charging the doctor for the reprint. That policy has held since we brought surgical guide fabrication in-house in 2022.

HOW IT IS BUILT

From prescription to seated case.

01

Prescription in

Send a scan file or a model with your RX. A technician reads your intent before any design begins.

02

Design & verify

We design to your margin and occlusion, then verify the fit against your prescription before it ships.

03

Build at the bench

Milled, pressed, or hand-layered as the case calls for, finished by a named technician.

04

Back to your chair

Pre-paid shipping returns the case ready to seat, with the technician reachable if anything needs an adjustment.

This is our standard pipeline. The exact steps for 3D-Printed Restoration are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for 3D-Printed Restoration, from zirconia and lithium disilicate to hand-layered porcelain, are being written up. Ask for a Doctor Kit and a technician will talk through the right choice for your case.

CASE WORK

Judge the work on its result.

Before-and-after case work for 3D-Printed Restoration is being photographed at the studio. The best proof is a case of your own. Send one and see the finish on your chair.

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COMMON QUESTIONS

What dentists ask about 3D-Printed Restoration

Which file formats does Dani Dental accept for 3D-printed restorations?
We accept STL, OBJ, and PLY files for surface-based restorations and provisionals. For surgical guide cases that require CBCT anatomy, we work from DICOM exports. If your scanner outputs a proprietary format like 3Shape DCM or iTero RCAD, contact your assigned technician before uploading and we will confirm compatibility or request a neutral-format export from your scanner software.
How fast is the turnaround on 3D-printed provisionals?
Standard turnaround from confirmed scan receipt to dispatch is 24 hours for single-arch provisionals and 48 hours for full-arch temporaries that require occlusal design review. Surgical guides run 2-3 business days because of the CBCT processing and guide fit-check step. Rush requests for provisionals can often ship same day if files arrive before 10 AM Arizona time. Call your technician to confirm availability.
What materials do you use, and are they biocompatible for intraoral use?
Dani Dental stocks three validated resin classes: a Class II bis-acryl provisional resin cleared for short-term intraoral use (up to 12 months), an occlusal splint resin with documented flexural strength data, and a surgical-grade photopolymer for guides. All materials are used within manufacturer-specified shelf-life windows and lot numbers ship with every case. We do not use unapproved resins to cut material costs.
Can you fabricate full-arch temporaries for All-on-X cases?
Yes. Full-arch temporaries for implant-supported cases are one of the most common 3D-printed requests we handle. The technician assigned to your case will confirm the screw-access channel positions against your surgical guide data, design the occlusal plane in exocad using your prescribed vertical, and route the final file through our marginal fit benchmark before printing. Turnaround is typically 48 hours from design approval.
How do you handle surgical guide fit verification before shipping?
Every surgical guide is seated on a reference model printed from the same DICOM file used to design the guide. If any sleeve site gaps or rocks beyond 0.1 mm, the guide reprints at our cost. The verified guide ships with the reference model and a case summary listing the sleeve diameters, drill protocol compatibility, and the technician's direct contact. This step has been standard practice since we brought guide fabrication in-house in 2022.
What if the 3D-printed restoration does not seat correctly at the chair?
Call the technician directly. The number is printed on the case summary in the box. Our remake rate on printed restorations sits below 2.5% for 2024, but fit failures happen and we do not hide behind a customer-service queue when they do. If the issue is a scan artifact or file problem on the doctor's end, we will walk through it together. If the problem is on our end, the case reprints at no charge.
Do you offer milling-as-a-service for labs that want to outsource their 3D printing?
Yes. Labs that have the design capability but not the validated print hardware can send finalized STL files to Dani Dental for production. We print to spec, finish to protocol, and ship under your case packaging if required. Pricing is per-unit with no monthly minimums for labs under 30 cases per month. Contact us to discuss volume tiers and turnaround SLA for your specific case mix.
How does 3D-printed restoration fit into Dani Dental's broader digital workflow?
3D printing is one node in a connected digital chain that also includes intraoral scan intake, CAD design in exocad, milled zirconia and ceramic restorations, and implant-supported prosthetics. A full-arch implant case, for example, may move from CBCT-derived surgical guide through printed provisional through milled final zirconia bridge inside a single workflow, with one technician coordinating each hand-off. That end-to-end accountability is the practical difference between a single-lab digital partner and a milling center.

REQUEST A DOCTOR KIT

Send us a 3D-Printed Restoration case.

Request a Doctor Kit and we will mail RX pads, a shade guide, and pre-paid shipping. Run your first cases through the studio and judge the result on your own chair.

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