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SLM 3D Printing in Dental Applications
The Complete Digital Dental Workflow by 2onelab
Selective Laser Melting (SLM) 3D printing has revolutionized dental applications by enabling the precise and efficient production of high-quality applications, such as RPDs, crowns, and bridges. The process consists of three key steps: pre-processing, processing, and post-processing, which we will explain below.
Pre-Processing
1. Scanning the Model
“Scanning the Model in the Dental Laboratory” is a key component for modern digital dental workflows and SLM 3D printing, creating a precise digital model for the printing process. A gypsum model or impression is scanned to generate an accurate digital file.
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– Preparation: The model is cleaned to remove contaminants; scanning spray may be applied to reduce reflections.
– Placement: The model is positioned in the scanner for optimal visibility; the settings are adjusted for precision and efficiency.
– Scanning: Optical or laser-based 3D scanning technology captures the model; multiple passes may be used and stitched together.
– Quality Check: The digital model is reviewed for completeness; rescanning or software refinements if needed.
-Storage & Archiving: Saved in standard formats (STL, OBJ) for CAD processing and archived for future use.
2. STL File Creation
To create an STL file for 3D metal printing, specialized CAD software like Exocad, 3Shape Dental System, or SilaPart is used to process and export precise digital models.
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– Processing: The scanned 3D model is optimized in CAD software (e.g., adding supports, refining thickness, checking geometry).
– Adaptation: Printer-specific requirements (detail sizes, surface quality) are considered.
– Export: The model is converted into an STL file with a balanced resolution for precision and efficiency.
– This ensures the STL file meets all requirements for high-quality SLM 3D printing.
3. 2Build – STL File Preparation
In 2Build, the STL file will be prepared for the print and processed into G-code, which provides precise instructions for the metal 3D printer.
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– Import & Error Check: The STL file is loaded into the 2Build software and checked for issues (e.g., incomplete geometries, inverted normals), with fixes applied if needed.
– Positioning: The model is aligned within the virtual print space to optimize material use, print time, and support structures.
– Support Generation: Automatic support structures stabilize overhangs, with manual adjustments possible for efficiency.
– Print Parameters: Settings like layer thickness, speed, laser power, and internal structure are configured for optimal printing.
– Simulation & Verification: A test run detects potential issues, estimates print time, and ensures stability.
– G-code Generation: The finalized instructions are saved and transferred to the 3D printer via network, USB, or other storage.
– This streamlined process in 2Build ensures the STL file is optimally prepared for high-quality and precise SLM 3D printing.
Processing
4. 2Create – Set Up & Printing
The SLM 3D printer 2Create is set up by configuring the machine, loading metal powder, and adjusting key parameters for a smooth printing process.
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– Cleaning & Inspection: Residual materials are removed; build platform, powder containers, and filters are cleaned and aligned.
– Parameter Configuration: Settings like layer thickness, laser power, and scanning speed are adjusted based on material and model complexity.
– Powder Bed Preparation: A thin, even layer of powder is spread to ensure a smooth first print layer.
– Final System Check: Gas supply (argon/nitrogen), oxygen levels, filters, and the laser system are inspected.
– G-code Import & Validation: The file from 2Build is verified for compatibility before printing begins.
– SLM 3D Printing: The machine builds the model layer by layer based on G-code instructions.
– This setup ensures precise and high-quality metal printing under controlled conditions.
5. 2Create – Unloading & Debinding
After printing, the finished part can be removed immediately. There is no need for the machine to cool down, allowing the extraction process to start right away.
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– Chamber Venting: The chamber is vented to release any residual protective gas (argon/nitrogen), and pressure is equalized before opening.
– Safety Precautions: Care must be taken, as the build platform and surrounding metal powder may still be warm.
– Excess Powder Removal: Powder is vacuumed or brushed off and collected for reuse, minimizing waste.
– Initial Inspection: The part is checked for defects such as cracks, deformations, or incomplete sections.
– Machine Cleaning: Remaining powder is vacuumed, filters are cleaned, and the machine is inspected to maintain optimal performance for the next job.
– This process ensures efficient production and high-quality parts through careful handling and machine maintenance.
post-Processing
6. Heat Treatment
Heat treatment enhances the mechanical properties of 3D-printed parts by relieving internal stresses from the printing process, improving strength, durability, and structural integrity.
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– Purpose: Relieves internal stresses from rapid heating and cooling during 3D printing.
– Handling: The printed part and build platform are carefully removed and inspected for any loose powder or debris.
– Furnace Setup: The part is placed in a heat treatment furnace with precise temperature control.
– Treatment Profiles: The process includes stress relieving (500-650°C) or annealing (higher temperatures for improved ductility).
– Temperature Control: The part is heated to the target temperature and held for a specified time to stabilize the material.
– Cooling: The part is cooled gradually or via controlled air cooling, depending on desired properties.
– This post-process of selective laser melting (SLM) helps preventing warping, cracking, and ensures dimensional stability.
7. Bandsaw – Removing the Part
After the heat treatment (or annealing) process, the next step involves removing the part from the build platform and detaching any support structures.
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– Purpose: After heat treatment, the part is removed from the build platform and support structures are detached. Once cooled, the part is ready for detachment.
– Cutting: A specialized saw, such as a bandsaw or wire cutter, is used to separate the part from the platform. .
– Care: The saw must be set correctly to avoid damaging the part or causing stress that could lead to cracks.
– The build platform is often metal, requiring careful cutting to prevent damage to the part.
8. Supports Removal
Once the part is detached from the build platform after SLM printing, the next task is to remove the support structures.
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– Tools: Cutting tools, such as saws or pliers, or grinding tools are used to remove supports without damaging the part.
– Grinding Machine: In some cases, a grinding machine is used to polish off the attachment points, ensuring a smooth finish.
– Multiple Stages: The process may involve several stages of cutting, grinding, and polishing, depending on the complexity of the part.
– Final Cleaning: The part is cleaned thoroughly to remove any debris before any additional post-processing, such as polishing or coating, is performed.
– The part is fully prepared for the final inspection and further use or assembly.
9. Preparing for Polishing
Before the 3D-printed part can be polished, all remaining support structures must be carefully removed and the part should be thoroughly cleaned.
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– Tools: Use a Dremel or similar tool to refine details and remove excess material.
– Cleaning: Clean the part with compressed air or a soft brush to remove dust and grease.
– Smooth Surface: Ensure a clean, smooth surface for the best polishing results.
10. Polishing
After the part has been detached from the build platform and the supports have been removed, the next step is polishing the part to achieve a smooth, high-quality surface finish.
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– Method: DLyte electrochemical polishing smooths surfaces using an electrolyte solution and electrical current.
– Process: Removes material evenly, ideal for complex geometries.
– Preparation: The part is cleaned before being placed in the DLyte machine, where settings are optimized.
– Benefits: Creates a smooth, corrosion-resistant surface with reduced friction and improved durability.
– The final check ensures quality, with optional post-processing like coating or coloring.
Success Stories
Success Story NEO Lab
Learn how NEO Lab increased its RPE output with our 3D Metal Printer 2Create Plus by leveraging 3D printing and workflow simplifications in orthodontic care.
Success Story with Creacam
Discover how Creacam has redefined efficiency in dental production with our 2Create metal 3D printer, while cutting costs and ensuring consistency!
products
SLM 3D Printers
2Create
High-Precision Metal Dental 3D Printer
Mass production efficiency in a compact design, offering high precision, while ensuring quality and cost-efficiency. Ideal for dental technology as well as R&D.
2Create Plus
Compact Metal 3D Printer for Maximized Output
The 2Create Plus enhances productivity with a larger platform for expansive production needs. Elevate output for dental, medical and industrial applications.
