3D Printing Archives - The Ortho Cosmos

The Impact of 3D Printer Accuracy on Clear Aligner Therapy

September 20, 2019 by Scott Frey Leave a Comment

The Impact of 3D Printer Accuracy

In previous posts we have covered the accuracy of various 3D printers on the dental market in great detail as it pertains to the dimensional trueness of a single, static 3D printed object. However, it is also important to understand how 3D printer accuracy impacts the clinical outcome of dynamic treatments like clear aligner therapy. When fabricating a series of clear aligners to incrementally align the teeth, the dimensional inaccuracy of each 3D printed model is compounded between aligner stages thereby making 3D printer accuracy an even more important consideration. Although the directionality of the error is not necessarily consistent, the magnitude of print inaccuracies between stages could be up to double that of single print. Thus, despite the dimensional error of even the least accurate 3D printers being well within the reported guidelines for accuracy for orthodontic casts of 300µm, the maximal error possible with clear aligners can approach and even exceed this limit with lower accuracy 3D printers.

In addition to the understanding the benefits of using more accurate 3D printers to manufacture clear aligners in-house, 3D print inaccuracies must be taken into consideration when designing maximal tooth movement velocities or activation rates for in-house clear aligner treatments. Since most quality 3D printers exhibit average dimensional inaccuracy on the order of 50-70µm, clinicians must account for the possibility of 0.1mm variance in the planned maximal activation rates. Based on the available data, it would be advisable to revise maximal tooth movement velocities down to 0.15-0.2mm of linear displacement per stage.

As in-house clear aligner software continues to evolve, machine learning and artificial intelligence will assist in the design of more effective movement staging and activations (as products like Invisalign are already doing), but the increased accuracy of 3D prints from quality 3D printing machines will always provide an advantage for clear aligner therapy.

A Simple Formula for Lean Manufacturing Operations with 3D Printers

September 14, 2018 by Scott Frey Leave a Comment

The Ford Production System paved the way for most modern lean manufacturing, and one of the best examples of lean manufacturing principles in action was the Willow Run B-24 bomber production facility during WWII. After intervention from Ford, the Willow Run Facility was able to go from producing just one bomber per day to one per hour. 24x their original output!

At the core of operational change was Ford’s “pacing clock” which monitored what we now call Takt Time (Takt time originates from the German word Taktzeit, meaning clock interval). Takt time provides you with the pulse of your operations – the rhythm and rate by which tasks and products must be completed to meet demand. By monitoring and setting guidelines for this single figure, Ford was able to build a manufacturing facility which was able to produce the same as half of the entire German aircraft industry….

Today I am going break down what Takt Time is, how to calculate it, and how to apply it to allocate 3D printer assets and labor to keep your 3D Print Farm running smooth.

The calculation itself for Takt Time is actually quite simple….

T = Ta / D

“T” represents Takt Time, which is the maximum time you have from starting one process until needing to start on the next in order to meet demand. This doesn’t have to be a whole number, but the units you use should be the same as those for the “Ta” figure (minutes, hours, days, etc).

“Ta” shows the total available work time during a given work period. This figure can be confusing, but the important thing to remember when calculating it is that this should only include time when value is being added through work.

“D” represents the total demand for units during a given work period.

With this formula you can now easily determine the maximum time that it takes to produce a particular item in order to keep up with demand. It also allows you to identify bottlenecks within our overall operations by applying the concept of Takt Time to individual processes. However, in order for Takt Time to be both accurate and applicable, it is important to understand that there must be a few constants in the system being assessed.

Customer demand must be relatively constant over the work period
All requested products must be similar (or take the same amount of time to create)

Typically these constants aren’t a problem for a simple system, where a singular product is being made. However, complex systems, tasks, and products involving multiple parts should be broken up into smaller cycles for Takt Time to be correctly applied.

One last aspect to mention before diving into an example is that of buffer time. Buffer time is a vital and often overlooked aspect of Takt Time calculations because there will always be problems that we can’t predict. The key to making any process or calculation flexible enough to roll with the punches in the real world is to account for the unknown and allow for enough leeway to maneuver in case of disaster. Instead of planning for work cycles to be exactly the same as Takt Time, we should instead aim for them to be around 92-95% of that figure. The shorter your Takt Time, the larger your buffer time typically should be to ensure that you have sufficient wiggle room.

Now let’s take a look at how we can apply all this to 3D printing operations in your digital orthodontic lab and determine how many 3D printers you will need to meet your production needs.

In order to do this, we must begin by also performing a calculation of the Cycle Time (the the length of time on average it takes to complete a step or set of steps within an operation) for each 3D printer you own or are considering purchasing. Since 3D printers can operate overnight without human supervision the easy way to perform this calculation is by dividing the Total Daily Throughput for a given printer by the Number of Minutes in a 24 hr Working Period. This will give us the following Cycle Times per model for several 3D printers commonly used in orthodontics:

In order to meet monthly demand for model production these Cycle Times per model must be kept below the target Takt Time. If cycle times need to be reduced, additional 3D printing assets will need to be acquired. For each additional 3D printer that is purchased, Cycle Times will drop accordingly since daily throughput would increase.

So if for example we project that we need to print 1000 models each month and we have 3D printers that will be operational and printing for 18 days out of the month (convert over to minutes), how many printers will we need in order to consistently meet this demand level while allowing for 5% buffer time?

If we have a print farm consisting of Formlabs Form2 printers, a monthly output level of 1000 orthodontic models will require three Form2 printers.

If we have a print farm comprised of both Form2 and Moonray 3D printers (this allows for a more customizable and modular print farm), one Form2 and one Moonray is sufficient to handle these printing needs.

One of the most common rookie mistakes that I see people making when starting off with 3D printing workflows is using digital platforms in the same manner as the analog tools they have been using. Trying to scan and print same-day 3D models as though you were taking an impression and pouring up a set of models in plaster does not scale and is not how you should be implementing digital technology. Attempting to utilize 3D printers routinely for same-day models has a Takt Time of 28min and will artificially create huge demand that is difficult to handle. This workflow simply does not scale. What should be done instead is using digital tools as they are intended to save time and visits by manufacturing ahead instead of scrambling due to poor planning.

As you can see applying the concept of Takt Time is very useful for designing a 3D print lab based on lean manufacturing principles. Additionally, Takt Time can be just as easily applied to non-physical tasks (i.e. ClinChecks, IDB Set Ups, model processing, and other digital tasks) because it is a consistent measure of the rate of progress, much like keeping tabs on the heartbeat of your company. We have also examined how Takt Time affects your capacity to scale digital workflows with clear aligners.

The Layers of Technology

October 6, 2017 by Sean Holliday Leave a Comment

There is a fun line in the movie Shrek: Ogres are like onions because they have layers. This reminds us not to take things at face value. Consider that scary piece of technology also has layers of opportunity. When I talk to many doctors about implementing pieces of technology in their practice, there is a common theme where leveraging that capital investment falls short as a value add.

Take into consideration that the digital space offers many opportunities outside of the analog world we are used to. The layers I refer to are best explained when you think about the use of a smart phone or smart watch. If your intention with a smartphone is simply to make better phone calls, you are missing the big picture. A smart watch is also a piece of technology that is not intended to just tell time. If I wanted a timepiece, then there are probably much more elegant devices out there that do the job. The smart watch integrates apps and layers of functions that measure my heart rate, remind me to take a break to breathe, measures the number of steps I have taken, tracks my golf swing, sends me messages, links to my calls, integrates with my car, sends me reminders, and with a voice command serves as my personal assistant.

Beyond phones and watches, many of us are integrating pieces of technology in our practices. They become a means and not an end. These tools are often used as an alternative to an analog process, where the layers of benefit are often missed:

Intraoral Scanning

If your focus on scanning is to replace alginate or PVS impressions, then you are missing several of the benefits this technology offers. The impression is a basic benefit. We often take a digital process and integrate it to replace an analog one without implementing the added layers this equipment delivers. Most intraoral scanners offer several different add ons that build value for both practitioner and patient. The Trios scanner, for example, offers full color images in 3D, where this could replace intraoral photography. The outcome simulator Trios will be offering as well as the iOSim iTero has integrated into their device suddenly offers a layer of benefit to the patient on boarding process and treatment presentation. The digital and visual treatment presentation tool now delivers a new workflow in planning treatment, progress tracking, retention and post-tx monitoring.

CBCT

I have heard that once you go 3D, you will never go back to 2D. That is clearly a benefit in a diagnostic tool. I see many doctors taking a CBCT and reconstructing 2D images to get back to our comfort zone. In that case, I can see the argument that a pan and ceph have lower doses, lower costs and similar benefits for the average patient. It’s like using that smartwatch simply to tell time. The benefits of 3D imaging expand the layers of benefits to view cases differently and open up the transverse plane, better perception of asymmetries, fewer artifacts, volumetric measurements, and a better representation of the actual patient we are treating.

Aligner Therapy

Let’s tackle the obsession with aligners vs. braces, are they comparable in outcomes? As orthodontists begin to actually learn how to use this technology, and the technology improves in predictability, we start seeing the destination of both appliance systems becoming more similar and equal for some of us. If we leave it at that, then we have also missed the added layers of benefits aligner therapy systems offer to patient experience, practice efficiency, and practice growth. If you are offering aligners as an alternative to braces, then you are leaving a lot on the table and similarly using a smartwatch to tell time. Clear aligners are less about the clear part, and more about the journey. A braces practice and an aligner practice cannot operate with the same systems. The scheduling, clinical flow, CAD workflow, treatment presentation and marketing efforts are not the same. Trying to fit the round peg of aligner therapy into the square hole of brackets and wires continues to frustrate many who wonder why they can’t see beyond the high lab fee. If you are working to implement aligner therapy in your practice, don’t forget about those layers beyond the exterior.

Fixed Appliance Therapy

Let’s not forget that brackets and wires are still the most common tool used in the orthodontics today. Treatment becomes less about moving teeth, than on the layers added to the treatment experience. Orthodontists are more than just tooth movers, and we must consider how the choice of fixed appliances can save time, save office visits, change perceptions and enhance the motivation to achieve the desirable result. There are many layers of opportunity in the development of fixed appliance technology.

3D Printing

The integration of 3D printing still makes many rant that it is a useless digital toy that is an expensive alternative to plaster. Again, the analogy applies. If your limitation in using additive manufacturing for printing models is to replace plaster models keeps proving my point about missing the layers of benefits. Additive manufacturing will continue to disrupt the orthodontic lab industry in ways we have only started to imagine. The availability of free/cheaper software solutions, faster turn around and full control of the CAD/CAM process within the average orthodontic practice have more layers of benefits than I can put into this post. As stated above, taking this tool and making it fit into the analog process and traditional scheduling and orthodontic methodologies misses most of the benefits that add layers of value. Manufacturing in-house changes the game, period.

These are but a few of the technologies out there that I see don’t get their due acknowledgement. We keep comparing them to the traditional methodologies, where their potential to improve our specialty are not fully realized. The benefit of time is that it is a constant, and the inevitable progress will continue to move forward whether we embrace it or not. Across industries and professions, technological innovations will continue to add to the layers of benefits being offered and change the landscape.

Details on the myiTero.com Update

July 12, 2017 by Scott Frey Leave a Comment

A Unified Platform

The concept behind the myiTero.com launch is to bring the entire Element interface onto the web and begin the process of unifying the IDS (Invisalign Doctor Site) and iTero platforms into one ecosystem. With the myiTero portal you will be able to everything except scanning from the browser on either your desktop computer, phone, or tablet. The Outcome Simulator, while able to be launched from the web, still requires a Windows machine with the right graphics card to run. There is also a Learning Center for your team, and settings tab to define settings for Exports of iRecord and iCast files.

Just like on your iTero Element you can select a patient’s file to bring up a history of all the scans taken for that patient. By selecting a particular scan you can open the viewer, which brings up an iTero Element style interface, or export the STL file to send to your 3D printer or to a lab.

The turnaround time for everything to be available is now only a few minutes after the scan is taken, and the transition of this access away from the physical iTero is important because it frees up the scanner for the next patient quickly. Currently the scans available through the viewer are not in full color, but that will soon change, creating a superior alternative to intra-oral photos. For the time being though, you can certainly show patients accurate bite relationships and occlusal contacts as well as open the Outcome Simulator on your Windows machine as before.

Occlusal Contacts Invisalign Scan — Occlusal Contacts

Now that this information is accessible through a cloud based portal within minutes it is worth re-examining your initial consultation process to allow for patients to be scanned from the beginning so the 3D data can be used as a teaching tool. For us Mac people, we still have to wait a little bit to be able to fully leverage the Outcome Simulator. Very soon, using the proposed outcomes from simulator to help your technician with your initial Set Ups, sending for appliances or Indirect bonding, a GP making a referral to orthodontists on the doctor locator, or starting the patient that day as an orthodontist will be as easy as pressing a button.

The ROI of 3D Printing in Orthodontics

July 10, 2017 by Scott Frey Leave a Comment

Return on Investment of 3D Printers

Any time a new technology starts building steam, we need to avoid getting caught up in the hype and must determine whether there is a real and measurable return on investment that benefits your practice and your patients. When it comes to 3D printing in orthodontics, not only is it the real deal, but the investment required to make the leap has dropped to the point where it has become a no brainer for your practice.

We are going to explore the numbers in the post today, but the reasons to integrate 3D printing technology boils to three main factors: improved patient experience, increased ROI from in-house manufacturing, and enhanced treatment efficiency.

The rest of this post is available only to orthodontists and orthodontic residents registered with the Ortho Cosmos

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Accuracy of iRecord vs Invisalign Scans

June 13, 2017 by Scott Frey 1 Comment

iRecord Scan Accuracy

Many of you have probably heard that you should always use the dual scan capability on the iTero when scanning for appliances or 3D printed models because the iRecord scans are “less accurate.” I have heard this as well so naturally, I raised this question with the iTero engineers on a call last week discussing their scanning technology and development timeline.

As it turns out, there is no difference in data capture or in accuracy between the iRecord and Invisalign scans. However, up until recently, voids were not visualized on the iRecord scans, while voids have always been displayed on the Invisalign scans. Since gaps in data were not being displayed with standard iRecord scans, scans were being submitted with lots of voids and the software was having to compensate for these lower quality scans. Many orthodontic labs were receiving these files as well giving them a false impression about relative scan qualities between intra-oral scanners.

Fortunately, this issue has been fixed by recent updates for the Element scanner, but most doctors are completely unaware about these changes and how to insure that they are activated. To activate the data alerts on the iRecord-only scans, simply hit the toggle to the upper left of the dental arch selector. There is a similar toggle to the lower left of the dental arch selector that activates and inactivates the colors scans as seen in the image below.

As you can see when the voids are colorized they are far easier to see, and you can much better assess scan quality before submission. Without the color in the image below on the left, smaller voids and especially inter-proximal voids could be easily missed.

When the scan is in full color mode as opposed to the standard greyscale scanning mode, the voids will appear blue rather than red.

It is important to note that these updates (and will be the case other future software updates), are only available on the iTero Element scanner. Thus, if you are scanning for iRecord models on either then 1st Gen or 2nd Gen iTeros you will want to use the dual scan mode or very carefully review the scan quality before submission.

3D Printer Maintenance – Bottom Up Printers

June 9, 2017 by Scott Frey Leave a Comment

Caring for Your 3D Printer

One of the benefits of ‘bottom-up-and-peel’ style 3D printers is that they tend to have fewer mechanical parts that require attention. However, all 3D printers requires proper care and maintenance to continue humming along well and turning out accurate prints. When you purchase and unbox your new printer you’ll receive some additional instructions from the manufacturer about upkeep, but here are some good rules to follow when caring for key components in these types of machines.

Maintaining Resin Tanks

Bottom-up printers require a peel step between each layer to release the freshly cured layer from the build window at the bottom of the resin tank (typically made out of silicone) so over time the material on the build window will being to ‘cloud’ significantly and require replacement. How long the resin tank lasts is a factor of the build window material, the properties of the resin, and the number of peel steps that occur over a particular region on the build window. The build windows in the Form2 resin tanks are rated for 5000 peel steps with their V3 resin, so the rough math is one resin tank per resin cartridge (you want to keep them paired off) to maintain high quality prints.

You can extend the lifetime of your resin tank by printing with the largest acceptable layer thickness (Z Res) without compromising accuracy (100microns for orthodontic models), and by varying position of your prints on the build platform to more evenly utilize the build window. The Form2 dashboard can help you watch for even utilization by showing you a heat map of your prints on that particular resin tank as you can see below. Once they integrate this data into the PreForm software it will be even more useful.

It goes without saying that you should handle the resin tanks while wearing gloves and avoid touching the curing window. Fingerprints, dirt, or any smudges that could interfere with the light transmission through the curing window will negatively impact your prints. If you were to accidentally smudge the underside of the curing window, you must clean it using Novus 1 acrylic cleaner on a paper towel or microfiber cloth.

Isopropyl alcohol should not be used on any of the acrylic surfaces because it can cause cracking, and no chemical cleaners should ever be used on the inside of the resin tank since it could impact print resins. The resin tanks are more of a disposable item so cleaning the inside is largely unnecessary. If bits of cured resin were to find their way into the resin tank due to a failed print, you should filter them out by pouring the resin through a 190 micron paint filter.

Mirrors and/or Projector Lens

High quality optics are important for accurate and successful 3D printing, so you will need to avoid introducing dust or dirt into the machines and be careful not to smudge optical surfaces with residual resin or oils from your hands. The optics deck on many newer 3D printers are sealed to help avoid dust getting in, but either way you should keep the lid closed on your printer as much as possible to keep dust from getting in.

While changing resin tanks or in the even of a failed print, the mirrors and/or projector lens should be inspected to make sure they are in fact clean. If they were to become dirty, a damp microfiber cloth or compressed air dusters can be used to clean their surface.

Build Platform

Build platforms are extremely resilient and rarely need to be replaced during the lifetime of your printer. As long as there aren’t sharp bits sticking out from part removal/resurfacing that may puncture the silicone curing window in the tank, there is no need to replace the build platform, but they should be cleaned throughly with a cloth between prints. Chemical cleaners should not be used on the build platform to avoid introducing them into the resin during printing.

General Upkeep

Although this would be rare in an orthodontic lab, if the resin sits for longer periods of time it may need to be gently mixed to avoid settling of particles with some types of resins. In the Form2, you can simply remove the wiper and gently sweep it left and a right to make sure the resin is mixed. It is a good idea not to mix it while in the machine in case of a spill so you should remove the resin tank prior to mixing. Outside the machine, you should keep the resin covered as much as possible.

Although isopropyl alcohol is used to wash printed parts and remove residual resin and is readily available, it should not be used to clean any of the acrylic parts on the machine like the hood or resin tanks. The isopropyl alcohol will crack the acrylic over time. Instead these acrylic surfaces should be wiped down with an acrylic cleaner like Novus 1 on a paper towel or microfiber cloth.

Look Out Labs Change is Coming

May 25, 2017 by Scott Frey 1 Comment

The Future of Orthodontic Labs

3D printing and computer aided design (CAD) tools are making orthodontic lab work easier to bring in-house and streamlining manufacturing by reducing the number of physical steps required to make appliances. This technology will significantly change how orthodontic care is delivered and the role orthodontic labs play in the marketplace.

To be able to assess the impact this will have on orthodontic labs themselves, we need to understand first the overall breakdown of the lab work they are currently performing. We were able to compile data from 8 orthodontic labs, ranging in size from one man operations to very large labs consisting of 100+ lab technicians, which gives us a pretty good sampling of the products produced by traditional orthodontic labs across the US.

The average data by appliance category for the labs surveyed is represented below:

Appliance Type	AVERAGE
Hawley Retainers	45.4%
Spring Retainers	4.4%
‘Invisible’ Retainers	3.3%
Fixed Lingual Retainers	3.0%
Functionals	2.4%
Occlusal Splints	2.0%
Expanders	11.6%
Habit Appliances	1.0%
Space Maintainers	3.8%
Class II Correctors	6.4%
Clear Aligners	6.6%
Tooth Positioners	4.5%
Indirect Bonding	2.0%
Other (Study models, Mouth guards, etc.)	3.7%

Among the data, there were some other interesting findings:

As the size of the lab decreased, the product mix shifted heavily towards Hawley retainers. Large labs would top out at about 20% Hawleys where as some single person labs saw 90%+ in Hawleys.
Indirect Bonding and Class II Correctors (Herbst & MARA) were non-existent until you got into the larger commercial labs.
Expanders, both fixed and removable, topped out in the medium size labs before decreasing with the larger labs. This may be due to them being combined with Class II Correctors, rather than being listed separately as an expander.
Tooth positioners were also non-existent until you get into the larger labs in the market. Most of the universities are not utilizing tooth positioners anymore, thus small labs are not getting the demand to carry the product.

The appliances that are least technique sensitive to fabricate and those where significant advantages are gained by shifting work into the digital space are going to be most impacted by 3D printing. This will disproportionately affect the larger labs and primarily concerns ‘invisible’ retainers, study models, clear aligners, occlusal splints, and indirect bonding, which account for 13.9% of lab work performed by orthodontic labs based on the averages in our sample. Spring appliances may also be impacted if they are being done for tooth movement, since may doctors may opt to produce clear aligner in-house as an alternative. The appliances that will be least affected in the short term will be soldered and banded appliances since the advantages from 3D printing that would drive adoption aren’t as significant until such appliances can be directly printed.

How Orthodontic Labs Will Adapt

Given the significant impact that 3D printing technology will have on orthodontics in general, orthodontic labs will be forced to adapt. There are several ways in which we will see them changing their model:

Providing supportive digital services so practices can outsource their digital workload and storage. The practice would then have the option of either manufacturing the physical appliance in-house, or having the lab fabricate and ship the appliance as they do now. Some labs have already begun to implement this. Ideally, the global economy would be leveraged to have the digital tasks performed overnight to increase productivity.
Manufacturing and marketing direct-to-consumer products, either on their own or in partnership with other companies. Since these labs already have the infrastructure in place to manufacture and distribute products, this may be a natural transition.
Offering training services, both on-site and online, for in-house orthodontic lab technicians.
Focusing on products less affected by 3D printing. However, this is more of a delay tactic than a solution.

Using 3D Builder in Orthodontics

May 18, 2017 by Sean Holliday Leave a Comment

The hidden truth is that there are several CAD software platforms available that are free and can help with basic functions and improve the experience with 3D printing. The advantage is that even a novice can get their feet wet in the 3D printing arena and prepare prints that are effective and well prepared.

3D Builder is a CAD software available in Windows 10 that allows for several basic functions that serve in preparing models for orthodontic purposes. Let’s review a few functionalities:

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Print Farm Starter Kit

May 17, 2017 by Scott Frey Leave a Comment

3D Printer Shopping

Most of the companies and their reps selling 3D printers have been working in the dental space with restorative dentistry and implant dentistry and have not yet adapted to the substantial differences that exist with orthodontics. Additionally, the margins on the actual 3D printers are razor thin so companies will push items like expensive UV curing boxes (with huge profit margins) when post-curing may not be indicated and when inexpensive UV light boxes for nails salons may suffice.

Orthodontists are in need of greater clarity on what you should or should not buy to begin integrating 3D printing in your practice, so we put together a shopping list.

Print Farm Essential Items

1 x Formlabs Form2 3D Printer (Complete Package is $3499)

All the 3D printers we tested for accuracy in printing orthodontic models demonstrated the requisite precision for orthodontic indications; however, the Form2 was the most cost effective and has a wide range of resins available so it makes a good starter 3D printer.
With the Form2 you can predictably build 20 dental models vertically per day (two prints of 10 models), which easily translates to 300 models a month on 1 Form2 printer. As your needs grow, you can gradually scale up your capacity by adding printers to your print farm. Having a print farm also provides redundancy so if one printer goes down you have a back up.
The complete printer package includes a Resin cartridge, Resin Tank, Build Platform, Finish Kit, and One Year Warrantee

2 x Matte Grey V3 Standard Resin Cartridges (1 included with printer package, $149 for additional)

Cartridge system for easy switching between different resins.
This resin has highly accurate curing properties and is perfect for dental models.
One cartridge will print about 50-70 dental models depending on size, so we recommend getting two.

Additional Resin Tanks (1 included with printer package, $59 for additional)

The rule is 1 Resin Tank per Resin Cartridge. These stackable resin tanks (with lids – don’t throw these out) that can be easily removed to switch between resins. The printer will come with one resin tank included.
Since the resin tank will be partially filled with resin, you will want to keep the resin tanks with a particular cartridge of resin (you can label the lids). Simply remove and cover with their original lid for storage.
The silicone curing window on the bottom of the resin tank wears down with each ‘peel step’ and will eventually cloud and require replacement. The silicone window is tested to withstand 5000 ‘peels,’ which means that you will typically need to replace the resin tank after printing through a whole resin cartridge to keep your prints accurate (2 cartridges is sometimes a stretch). You should evenly utilize the build platform and vary your print position so that the silicone curing windows do not cloud pre-maturely.

Finish Kit (included)

The Finish kit includes a finishing tray and accessories to remove parts and perform a thorough alcohol wash while maintaining a clean workspace.

PreForm Print Preparation Software (included)

Free software that comes with the Form2 printer. Other printers will have similar prep software for their machine.
This software will prepare files for printing and optimize them for printing on the Form2. Simply lay out prints on build platform, use the support generating tool, and push to print via WiFi.
You will have to physically present to start a print on the printer (needs manual verification that build platform is in place, etc.), but you can utilize the online Dashboard to monitor print progress remotely.

Optional Print Farm Purchases

CAD software

Although STL files for dental models can be downloaded and printed without additional software, if you want to make design modifications to the 3D files themselves you will need additional software. This isn’t necessarily something you’ll need to do right away.
This includes movement of teeth to stage clear aligner tooth movement, digital bracket removal, fabrication of direct print indirect bonding trays, fabrication of direct print occlusal splint/retainers, modification of tooth and gum surfaces
Some options include Orthoanalyze, Orchestrate, Elemetrix.
If you elect not to purchase software, you can outsource these CAD services to labs (to remove brackets, etc.) and have them provide the STL files of the final product for printing and digital storage in-house.

Pro Service Plan ($499)

Although the Form2 is dead simple to set up and use, the Pro-Service plan can be helpful for orthodontists new to the 3D world.
You will get a customized training session to learn in the ins and outs of desktop 3D printing, priority phone and email support, and the ability to hot swap a broken printer (a good idea if you don’t have a second printer)

Orion Pulse Arc Welder & Argon Tank (~$2500)

For welding/soldering parts on printed models.
Instead of purchasing an expensive laser welder, pulse arc welders offer an effective means of welding on printed models without melting the print. Welds are sturdier than soldering, but are a different technique so it may take some training for your lab technician.

Siliform Separating Medium (~$260 for 8oz)

If you are going to be making Hawley retainers or other acrylic based products on the printed models, you will need a separating medium. However, the surface tension on printed models is different than plaster casts and traditional separating mediums won’t work as well.
There are certainly a lot of options that can do the job, but the one that we have found to work best has been Siliform. It is not cheap, but it is effective. You can order from Adell Corporation.
3D printing offers more advantages if you are sticking to thermoplastic retainers or direct printed retainers, so you may want to consider modifying your retention protocols.

Biocompatible Resin Cartridges (price varies depending on material)

Bio-compatible resins are only needed for printed final products that will be used in the mouth. You do not need a bio-compatible resin to print a dental model that will be used as a working or diagnostic model.
Bio-compatible resins are available for use in direct printed IDB trays, occlusal splints, analogs for autotransplantation, surgical guides, etc.
The Dental SG Resin ($399) is already available, but the upcoming Dental LT Clear Resin (~$500) will be a better fit for most orthodontic needs.

Form Wash ($499)

While you can perform an alcohol wash with the finish kit that is included, Formlabs has created a little alcohol jacuzzi for your finished prints that accepts a full build platform.
This is an optional purchase, but it automates the wash process and takes up less counter space than the alcohol baths in the Finish Kit so it may be useful. The agitation of the alcohol will also get a more thorough clean of the printed items in less time. By purchasing an additional build platform you can start another print immediately while the other build platform is being washed.

UV-Post Curing Box

If you are printing objects that are bio-compatible, you will need to do a complete UV post-cure. This can be done either with the Form Cure ($699) or the Kudo Post Curing Lamp ($249). Companies will typically push these whether or not your truly need them because they are high margin.

Additional Build Platform ($99)

Build platforms will last nearly indefinitely, but if you are looking to utilize the Form Wash System you will need a second build platform so you can print while your other build platform is being cleaned.