From calibration to curing, 3D printing requires precision at every step. Steve Lombardi, the Additive Manufacturing Manager for Absolute Dental Services in North Carolina, offers practical advice on how labs can refine their workflows to get the most out of their additive manufacturing investment.
Q: As an engineer, what do you wish that more technicians knew about working with 3D printers?
One of the key things I wish more technicians understood is the importance of calibration, maintenance, and post-processing in achieving consistent, high-quality results with 3D printers. It’s easy to assume that simply loading a file and pressing “print” will deliver a perfect product, but in reality, factors like build orientation, support structures, resin handling, and curing parameters can dramatically impact accuracy, surface quality, and mechanical performance. Understanding the whole workflow—from design to final post-cured part—is essential for reliability.
A common misconception among dental professionals is that all 3D printers are essentially the same, or that print quality is solely determined by the printer itself. In truth, material selection, software preparation, and even environmental conditions (like humidity or temperature) can play a major role. Another misconception is that 3D printing is “plug-and-play” for every application; while it’s powerful, it still requires thoughtful integration into existing lab workflows to be truly efficient and cost-effective.
Q: What do you think technicians should know before setting up 3D printing in their lab?
Before setting up 3D printing in a dental lab, it’s important to understand that it’s not just about buying a printer—it’s about implementing a complete digital workflow. Labs should be prepared to invest in more than just hardware. That includes software for design and slicing, a reliable wash and cure station, and proper ventilation or environmental controls depending on the materials used. Training is also essential; technicians need to know how to troubleshoot prints, maintain equipment, and manage materials safely and efficiently.
Additionally, labs should carefully evaluate what applications they want to support—crowns, models, splints, dentures, etc.—as each use case may require different materials and settings. Compatibility with existing CAD systems and the ability to scale over time are also key considerations. Most importantly, they should set realistic expectations: 3D printing can improve efficiency and precision, but it requires commitment to learning and refining the process.
Q: How do material properties affect the final product, and what should technicians watch out for?
Material properties play a critical role in the accuracy, strength, and durability of a 3D-printed dental part. Resin shrinkage, for instance, can lead to dimensional inaccuracies, especially in larger prints or precision-critical applications like surgical guides or crowns. Technicians should be aware that shrinkage occurs during both printing and post-curing, so proper compensation in the design or print settings—and adherence to validated workflows—is essential.
Layer bonding affects the mechanical strength of the final product. Poor bonding can result from underexposure, incorrect layer height, or contamination on the build plate or within the resin. This can cause parts to delaminate, especially under stress. Consistent exposure settings and clean printing conditions help prevent this.
Curing is another vital step: under-curing can leave a part too soft or prone to distortion over time, while over-curing can make it brittle or cause discoloration. Technicians should always follow manufacturer-recommended curing times and wavelengths, and ensure the part is positioned properly in the curing chamber for even exposure.
In short, technicians should treat material handling and post-processing with as much care as the print setup itself. Attention to detail in these areas is what separates a functional part from a failed one.
Q: What can technicians do differently to guarantee consistency in their printing?
To ensure consistency in 3D printing, technicians should develop and follow a standardized workflow for every print job. This starts with properly calibrating the printer and build platform regularly, as even small deviations can affect accuracy. Consistent handling of resins—like thorough mixing before each use and proper storage—is also critical, especially with light-sensitive or temperature-sensitive materials.
Print settings should be well-documented and matched to each specific material and application. Using validated workflows from manufacturers (when available) helps reduce variability. Equally important is the post-processing stage: consistent washing, curing times, and proper orientation during curing all play a big role in the final product’s mechanical and aesthetic quality.
Finally, maintaining detailed logs of prints—including issues, results, and changes in settings—can help technicians spot patterns, prevent repeat errors, and continuously improve print reliability.
Q: What is the most challenging part of 3D printing, from a maintenance or engineering point of view?
From an engineering and maintenance perspective, one of the most challenging aspects of 3D printing is ensuring long-term reliability and consistency across prints—especially when the equipment is used frequently in a production setting like a dental lab. Over time, small mechanical issues like Z-axis wobble, build plate misalignment, or wear on the light engine (in resin-based systems) can degrade print quality, often subtly and gradually.
Another challenge is resin contamination or degradation. Many users don’t realize how sensitive resins are to light, temperature, and repeated use. Improper storage or filtration can lead to failed prints or weakened parts, even if the machine itself is functioning correctly.
Keeping firmware, slicer software, and material profiles up to date is also a key but often overlooked factor. Each component of the ecosystem evolves, and failing to maintain them in sync can introduce avoidable errors.
In short, the biggest challenge is not a single failure point, it’s maintaining a high standard of preventive care across mechanical, software, and material systems to avoid cumulative issues that can impact output quality.
Q: What developments in 3D printing technology excite you most, and how might they impact dental labs in the next few years?
One of the most exciting developments in 3D printing right now is the rapid advancement of materials—particularly biocompatible, multi-functional resins that combine strength, flexibility, and long-term stability. These innovations are expanding what’s possible in dental applications, from same-day splints and dentures to permanent restorations with higher aesthetic and functional performance. As materials continue to improve, labs will be able to streamline production and reduce their reliance on milling or outsourcing.
Another major leap is in printer automation and real-time monitoring. Newer systems offer auto-calibration, integrated quality control, and even AI-driven error detection. This means less downtime, fewer failed prints, and more consistent outcomes—which is a huge win for high-throughput labs.
Finally, hybrid workflows combining scanning, AI-based design, and cloud-connected printers are transforming the speed and scalability of dental production. In the near future, labs may be able to handle more cases with fewer technicians while still improving turnaround times and precision.
These trends all point toward a more digital, efficient, and predictable lab environment, where 3D printing becomes a central part of the standard workflow, not just a specialty tool.
KEY TAKEAWAY
Viewing 3D printing as part of the full digital workflow-not just a plug-and-play solution-helps technicians and lab owners focus on additional factors that help guarantee more consistent, high-quality results.
Figures and Images
Steve Lombardi
