How is 3D printing used in dentistry?

Did your dental team just mention that your night guard or retainer could be 3D printed? A digital scan becomes a file that design software shapes, and then a printer builds the object one thin layer at a time. It can help dental teams make models and certain appliances, including some night guards and retainers.¹^,² 

What you will learn in this article: 

• How a digital scan becomes a printed dental object 

• Why a printed model is different from a printed appliance 

• How 3D printing can help make night guards and retainers 

• What to ask about fit, materials and care before taking an appliance home 

Schedule an appointment with an Aspen Dental provider to discuss your care options and the tools your dental team uses. 

How does dental 3D printing work? 

The process can be thought of in three stages: scanning, designing and manufacturing. 

First, the dental team needs a digital record of your teeth. An intraoral scanner can capture their surfaces directly. The digital data then goes into design software, where the dental team adjusts the design for the model or appliance to be made.¹

Next, a printer builds the object in thin layers. This differs from milling, where a machine cuts material away from a solid block. Some dental printers use light to harden liquid resin as each layer forms.¹

Printing does not finish the job. Depending on the device and material, additional processing may include cleaning and polishing. The U.S. Food and Drug Administration (FDA) reviews a material together with the finished device and what that device is meant to do.¹^,² 

What are 3D-printed dental models used for? 

A printed model is a physical replica of your teeth and nearby gum surfaces. It looks similar to a plaster study model, but a printer builds it from a digital file. 

Your dental team can print working models, and some appliances are formed over a printed model.¹ This distinction matters. Sometimes the printer makes a tool used during fabrication, rather than the item you will wear. 

Models also provide a snapshot of your mouth at a particular time. An older model may no longer reflect your teeth after orthodontic movement or new dental work. 

Can night guards and retainers be 3D printed? 

In some cases, yes. What varies is whether the printer makes the appliance itself or only the model it is shaped over, and that depends on the appliance and the material. 

How 3D-printed night guards are made 

Some night guards can be printed directly from a digital design. For resin appliances, finishing steps such as cleaning, additional light curing and polishing follow, depending on the material.¹^,² Ask whether your provider will check the fit and how your teeth meet against the guard before you take it home. 

Not every office prints in-house. Some send the digital file to an outside lab.

How 3D printing is used for retainers 

A retainer is meant to keep teeth in position, usually after orthodontic treatment. An aligner actively moves teeth. The two serve different purposes, even when they look similar.³ 

One approach uses a printed model as the form for a heated plastic retainer. In that case, the printer makes the model, not the retainer itself.¹ 

Some retainers can also be printed directly using a material intended for that purpose. The FDA has cleared at least one resin intended for manufacturing 3D-printed dental splints and retainers.³ 

The roles of night guards, splints and retainers differ, and printing is only one part of how each is made. 

What are the benefits and limitations of dental 3D printing? 

Digital files can be stored and shared with a lab, and printing has made some in-office production possible. Printing can allow more time-efficient treatment, though results vary by printer, material and process.¹ 

But printing is only one part of the process. It does not automatically mean a better fit, a lower price or a same-day appliance. Quality depends on the printer, the material, the software settings and the finishing steps.¹ 

The FDA clears materials for specific intended uses, so clearance for one use does not automatically cover another.² Ask about the finished appliance and its intended purpose, rather than whether the printer itself is “FDA-approved.” 

What should you ask about a 3D-printed dental appliance? 

If your dental provider mentions a printed device, these questions can help you understand the plan: 

• Why is this appliance recommended for me? 

• What material will it use, and is that material intended for this appliance? 

• Will it be made in the office or at a lab? 

• What is the total cost, including fitting and any adjustments? 

Talk with your local dental provider about your treatment needs and whether a printed appliance is an appropriate option. 

How is 3D printing used in dentistry? FAQs 

Can a lost appliance be reprinted from a stored file? 

Possibly. Ask whether your original file is still available and whether your provider can use it. Your teeth or bite may have changed since the scan, so ask whether you need updated records before a replacement is made. 

Does 3D printing mean you get your appliance the same day? 

Not necessarily. Design, printing, finishing and the fitting appointment all take time. An outside lab may also add shipping time. Ask your dental team when the appliance will be ready and whether another visit is needed to check it before you take it home. 

Do 3D-printed appliances need special cleaning instructions? 

Ask for instructions specific to your appliance, including which cleaning products to use and how to store it. Printed materials vary, so do not assume advice for a different guard or retainer applies. If the instructions are unclear, check with your dental team before trying a new cleaner or soaking solution. 

Sources 

¹ National Institutes of Health, Journal of Dental Sciences: “3D printing in dentistry – Exploring the new horizons.” https://pmc.ncbi.nlm.nih.gov/articles/PMC8189864/

² U.S. Food and Drug Administration: “Process of 3D Printing Medical Devices.” https://www.fda.gov/medical-devices/3d-printing-medical-devices/process-3d-printing-medical-devices 

³ U.S. Food and Drug Administration: “510(k) Summary—NextDent Ortho Flex.” https://www.accessdata.fda.gov/cdrh_docs/pdf22/K221022.pdf