Braces 3D printer: Technology, Market and Challenges

This article details braces 3D printers. It covers their working principle, price ranges, usage tutorials, and market prospects. With growing demand due to tech progress and increasing dental issues, challenges like high costs and lack of pros also exist.

Working principle of braces 3D printer

• Modeling process : First, use Computer Aided Design software such as CAD to create a 3D model of the braces. Other ways of obtaining 3D model data can also be used instead, such as scanning the patient’s teeth and using these scan data to convert into a 3D model. Dental 3D printed braces must be customized according to the teeth of each patient, so the accuracy of the model is crucial.
• Data conversion and input : Convert the created 3D model into a format that the printer can recognize (such as STL format), and then transfer the data to the 3D printer through SD card, USB flash drive or network connection.
• Printing process : This is the core part. The 3D printer has a nozzle device. After receiving the printing instruction, the nozzle will spray the “printing material” on the work platform in layers according to the pre-set thickness according to the program settings. However, the “printing material” here is not the ink of traditional printers, but materials such as liquid lithography resin, powdered nylon or plastic. As for braces 3D printers, most of them use photosensitive resins and other materials suitable for oral medicine applications and biocompatible. After each layer of “printing material” is sprayed according to the predetermined shape, the printer will perform some special processing internally. For photosensitive resin materials, photocuring technology (such as ultraviolet irradiation) is used to quickly solidify and shape each layer of material. Then the nozzle moves up a certain distance (layer thickness), and then prints the next layer. Layer by layer, until the complete braces model is printed.
• Post-processing stage : The newly printed braces model may require some post-processing. If there are support structures (structures added to support certain overhanging parts during the printing process), they need to be removed; the surface may also need to be polished to make the surface smoother and flatter, and the braces may be disinfected to prevent the risk of oral infection and other operations, and finally form a usable braces product.

Price range of braces 3D printer

• From the perspective of equipment performance and usage : If it is a basic entry-level desktop 3D printer, mainly used to print some simple braces models or for personal research and learning purposes, the price of such printers may be around 3000-10000 yuan. Their printing accuracy, speed, printable material types, molding area, etc. are relatively limited. For example, some small, single-function photosensitive resin light-cured 3D printers, but with the continuous development of 3D printing technology, these printers can also meet the requirements of some dental clinics or beginners for printing ordinary models of braces, such as making simple single tooth models for display or teaching purposes.
• Mid-range requirements (for small dental clinics or dental service stores) When it comes to requiring higher printing accuracy (such as printing accuracy around 20-50 microns), moderate printing speed, and the need to meet a certain amount of braces printing production, this requires better printer equipment, with a price range of about 10,000-50,000 yuan. Such equipment may be equipped with better printing nozzles, more precise positioning systems, and more stable feeding devices. For example, some mid-range light-curing 3D printers have a certain molding volume, which can print multiple braces models or more complex orthodontic models at once. They may also have certain automation functions, such as automatic feeding, automatic calibration, etc., to improve production efficiency and printing quality.
• High-end industrial-grade or professional dental medical equipment (for large-scale braces production enterprises or high-end dental medical institutions) : The price of this level of 3D printers is often above 50,000 yuan, and even some high-end models and configurations can reach hundreds of thousands of yuan. These printers usually have extremely high printing accuracy (up to 10 microns or less), ultra-fast printing speed, large molding volume, and can be compatible with a variety of advanced printing materials (to adapt to different biocompatibility, different mechanical performance requirements, etc.) as well as complex and advanced post-processing functions. For example, some large-scale DLP (digital light processing) 3D printers or equipment that uses special metal materials for 3D printing (such as titanium alloy, suitable for printing special braces parts such as implants) are often used in large-scale, high-efficiency, and high-quality production processes of braces, such as customized batch invisible braces for many patients or high-precision, personalized dental implant-related parts manufacturing.

Tutorial on Using Braces 3D Printer

• Preparation work
  • Equipment Installation and Inspection : Place the braces 3D printer smoothly on a suitable workbench, avoiding direct sunlight, proximity to heat sources, or equipment that is prone to vibration. Connect the power supply and ensure that the printer is well grounded for safety. When using it for the first time, check whether the various components of the printer are installed correctly, such as whether the print head is firmly fixed, whether the print platform is flat, whether the feeding device is smooth, and whether the internal light-curing device (if it is a light-curing 3D printer) is normal. At the same time, follow the instructions to initialize the printer, which may include steps such as setting the language and calibrating the initial position of the print head.
  • Choose the appropriate material : Choose the appropriate printing material according to the type and requirements of the braces to be printed. Common materials such as photosensitive resin materials need to pay attention to whether their physical and chemical properties meet the biocompatibility standards related to dentistry. If it is metal printing (which is relatively rare for braces printing, but may be used in some special braces parts), factors such as purity and strength of the metal material should be considered. The selected printing material should be correctly loaded into the printer’s silo or feeding system to ensure that the material conveying channel is not blocked.
  • Software preparation : Install the operation software that matches the printer (generally provided by the printer manufacturer), the functions of this software include slicing the model (cutting the 3D model into many layers of 2D images according to the printing needs so that the printer can print layer by layer in order), setting printing parameters (such as printing layer thickness, printing speed, support structure settings, etc.), and transferring the processed print file to the printer and other operations.
• Printing Dental Model Process
  • Acquire 3D model data : Use an oral scanner to scan the patient’s teeth. This scanning process will obtain 3D model data of the teeth; it can also be modeled according to the pre-made dental mold to obtain corresponding data. The modeling work can be achieved through CAD software or other dedicated 3D modeling software. After that, the obtained 3D model data is saved in a suitable format (such as STL format) for easy import into the printer operation software.
  • Import and process models : In the matching printer operation software, import the previously saved 3D model data file (STL format). Then perform slicing processing, which is very critical. When slicing, it is necessary to set the slicing parameters reasonably according to the material properties, printing purposes, etc. For example, if the layer thickness parameter is set thinner (such as 0.05-0.1 mm), the printed braces surface will be smoother and more delicate, but the corresponding printing time will increase; the setting of the support structure should be determined according to the shape and structure of the model. For models with overhanging parts or complex internal structures, support structures need to be added appropriately to ensure that the model will not collapse during the printing process, and the density and shape of the support structure can also be optimized to facilitate subsequent removal operations.
  • Set printing parameters and start printing : In addition to the parameters in the slicing process, there are other printing parameters that need to be set, such as printing speed (reasonably selected according to the complexity of the material and model. Generally, if the model is complex or the material needs a long curing time, the speed will be set slower), nozzle temperature (if it is a hot melt material printing, the nozzle temperature needs to be set reasonably to ensure uniform hot melt extrusion of the material. If it is a light-cured type, there is generally no such parameter), platform temperature (some printers will have it to ensure that the underlying material has good adhesion to the platform in the early stage of the printing process), etc. After all the parameters are set, the print instruction is issued, and the printer starts to print the braces model step by step according to the set steps.
• Post-processing stage
  • Remove the support structure (if any) : After the printing is completed, remove the printed braces model. If the support structure is used during the printing process, these support structures need to be removed first. When removing, try to use a way that does not damage the braces body and can clean and completely remove the support, such as some specially designed support structures, which can be removed by gently twisting or clamping with tools.
  • Surface Treatment : Polish the surface of the braces to make the surface smoother. The polishing can be carried out step by step with different mesh sizes of sandpaper (from coarse to fine) to ensure that the surface roughness meets the requirements so that it will not cause damage to the oral mucosa during subsequent use. If there are some defects or small pits on the surface of the braces, filling operations may also be required (using filling materials that are compatible with the printing material for filling).
  • Disinfection and Cleaning : Since the braces will eventually be placed in the oral cavity, disinfection treatment is an essential step. Disinfection can be carried out by means of ultraviolet disinfection, chemical disinfectant soaking (but pay attention to whether the material is tolerant and the disinfectant residue treatment), etc. The disinfection operation should be strictly carried out in accordance with relevant health standards and operating norms to ensure the safety of patients. If necessary, the disinfected braces can also be simply cleaned to remove possible residual disinfectant substances or impurities, etc. After washing and drying, they can be used for orthodontic treatment of patients.

The market prospect of braces 3D printers

Rapidly growing market size

Technological progress drives demand growth

• Improve accuracy and customization With the continuous development of 3D printing technology, the printing accuracy of 3D printers for braces is constantly improving, which can better achieve personalized customized braces. Some printers can achieve a printing accuracy of 20 microns or even smaller, which can make the orthodontic appliance more closely fit the patient’s teeth, and improve the wearing comfort while meeting the purpose of correcting teeth. Nowadays, many 3D printers for braces can directly convert the patient’s oral scan data into a 3D model for printing, without the need for complex production processes like traditional methods, which saves time and greatly improves accuracy.
• The Application Potential of New Materials : In the field of materials, whether it is transparent resin materials for orthodontics or metal materials (such as titanium alloys) suitable for special purposes such as implants, they are constantly developing. The newly developed materials have better biocompatibility and mechanical properties that are more suitable for the needs of oral environment. For example, some new photosensitive resin materials not only have good transparency and flexibility, but also have biocompatibility that is more acceptable to oral cells, which also prompts more medical institutions to be willing to adopt 3D printing braces technology.

Increase in market demand

• The demand for aesthetics and comfort has led to an increase in patients : Traditional braces, such as metal braces, can affect the appearance of patients, while 3D printed invisible braces greatly improve their aesthetics and have characteristics such as more comfortable wearing compared to traditional braces. This makes more and more patients who need orthodontic treatment tend to choose 3D printed braces, thereby increasing the demand for 3D printers to produce braces.
• Large base of dental diseases : Due to the increasing incidence of dental diseases such as tooth decay and periodontal disease worldwide, the population base that needs dental restoration, orthodontics and other dental treatments has increased, making the demand for braces continue to increase overall, which will also greatly promote the development of the braces 3D printer market.

Challenges and opportunities faced

• The initial cost is relatively high : For dental clinics or related braces manufacturers, the purchase cost of 3D printers is relatively high, especially for high-end, high-precision, and high-capacity 3D printer equipment. In addition, the supporting printing materials, software, and irregular equipment maintenance costs make the overall cost investment large, which to some extent limits some small clinics or enterprises that do not have strong funds from adopting braces 3D printing technology. However, from another perspective, with the continuous popularization of 3D printing technology and the intensification of market competition, the possibility of continuous decline in equipment and material costs is greater, which will also be an opportunity for its development.
• Shortage of professionals : Despite the rapid development of 3D printing technology, there is a shortage of composite professionals who are proficient in the operation and maintenance of 3D printers, especially the specific operations of braces 3D printers (such as oral scanning data processing and printer adaptation, printing special material braces, etc.) and have relevant dental knowledge. On the one hand, this will lead to problems such as failure to repair in time and unsatisfactory printing effects during equipment use, affecting the user experience and market expansion; but at the same time, this also provides potential business opportunities for relevant 3D printer manufacturing companies and the dental industry to carry out targeted talent training business.