Milling thermoformed dental splints

Preparing the blanks: Overview

Prerequisites

• Suitable dental arch model as STL file from a CAD application

• 3D printing equipment for creating the dental arch model

• Equipment for thermoforming dental splints

Implementation

1. Create a job in TrimCAM with the dental arch model from your CAD application. Make sure that the requirements for the STL file are met.

    Creating new jobs

    Requirements for STL files

   TrimCAM adds a vhf-specific mount to the bottom of the dental arch model, for fastening in the machine.

2. Using the 3D printer software, import the modified dental arch model from TrimCAM. The STL file is saved to the export directory that was assigned during the installation of TrimCAM.

    Installation

3. Print the dental arch model with your 3D printer. Make sure that the requirements for the 3D printout are met.

    Requirements for 3D printing

    Check the 3D printing quality with a test specimen

4. Thermoform the dental splint. When doing this, ensure the following:

   • The dental arch model is positioned in the center of the device.

   • The dental arch model lies on a flat surface and is not embedded.

5. Check if the finished blank meets the requirements for successful machining.

    Requirements for the finished blank

Requirements for STL files

• Use your CAD application to make sure that the exported STL file meets the following requirements:

• The STL file may only contain one object. Combine existing sub-objects (e.g. individual teeth) into one object.

• The dental arch model must be adequately high for trim line placement.

• The dental arch model must not contain any holes.

  

• The dental arch model must not contain any cross braces between the rows of teeth.

  

• The bottom surface of the dental arch model must be flat.

• If the dental arch model is hollow, the wall thickness must be at least 1.5 mm.

  

• Labels on the teeth should be raised.

• Labels on the gums should be recessed.

• Labels must be placed at a sufficient distance to the desired trim line.

• Labels must not be applied to the bottom surface of the dental arch model.

• The file name may not contain any umlauts or special characters.

Requirements for 3D printing

• Please note the following when preparing the model for 3D printing:

• The best milling results are achieved when the underside of the model is not modified and support structures are avoided.

• If support structures are necessary:

  • Support structures on the flat underside must be able to be removed without residue.

  • Do not place support structures into the mounting bracket.



Orange: Only removable support structures
Red: No support structures

• If a drainage opening for resin is required on mounting bracket, this must be placed in the large recess of the mount.

• Do not use raised labels / markings.

• To ensure that blanks are securely mounted in the machine, check your print settings using a test specimen if necessary.

   Check the 3D printing quality with a test specimen

• Prepare the dental arch model after printing:

  NOTICE! Pay attention to the information on cleaning and curing in the documentation for the printer and the resin.

1. Resin printer: Clean the dental arch model before final curing. In particular, remove all residue from the mounting bracket. Use a brush if necessary.

2. Resin printer: Allow the dental arch model to cure for the last time.

3. Check if the geometry of the dental arch model is correct.

    Requirements for the finished blank

4. Remove the support structures completely.

5. Filament printer: If necessary, remove residue from the transitions between contours.

Check the 3D printing quality with a test specimen

The print settings and the resulting quality are crucial for securely mounting the blanks in the machine. In particular, the so-called elephant foot effect can impair the mounting bracket of the blank. Excessive expansion of the first printed layers results in a deformed model.

To check the print quality and ensure successful mounting in the machine, you can create a test specimen and test the mounting. The test specimen is available here:

Download

 

1. Print the test specimen using the settings you normally use for blanks.

2. Prepare the test specimen as you normally would for blanks.

3. Position the test specimen perpendicularly in the machine:

   1. Guide the test specimen with the base facing downwards over the pressure piece.

   2. Press the test specimen onto the blank holder until the base rests on it.

   

    

   

    

4. Check the following:

   • No elephant foot effect is visible.

     

      

     

      

   • The test specimen can be pushed over the pressure piece until the base rests on the blank holder.

   • The base of the test specimen rests flat on the support surface.

   

    

   • The test specimen sits firmly and does not wobble.

5. If necessary: Change the print settings and repeat the test. If necessary, contact the manufacturer of your 3D printer.

6. Use the determined print settings for printing blanks.

Requirements for the finished blank

• Make sure that the finished blank fulfills the following requirements. Otherwise the machining may not be successful.

• The dental arch model is located in the center of the finished blank.

  

   

• The mounting bracket is correctly designed and symmetrical.

  

  Correct mounting bracket

  

  Asymmetrical mounting bracket

  

  Mount with recesses that are too small / inaccessible

  If there are errors, you should check if they are already included in the STL file from TrimCAM or if the errors occurred during 3D printing.

• The blank is free of irregularities on the underside and the mounting bracket is free of residue.

• During mounting into the machine, the blank locks firmly onto the blank holder and can no longer be moved.

What's next?

 Mounting and removing blanks