Revolutionizing Dentistry: 3D Printing Advances Dental Applications

„Thanks to the advanced 3D printing technology, we've reduced our production time significantly, which means patients get their custom devices faster than ever."

Jesús García Urbano | CEO Ortoplus

Challenge

Treatments for bruxism typically involve stress management techniques, physical therapy, and the use of oral devices such as occlusal splints. However, for patients and dentists, the process can often be very cost- and time-intensive. Despite the effectiveness of occlusal splints, adherence to treatment can be low. Common reasons for discontinuing treatment include discomfort, difficulty keeping the splint in place during the night, and issues with fit or breakage. Due to the effort involved in traditional manufacturing processes, the untreated progression of bruxism often leads to extensive dental damage, requiring costly restorative treatments. Additionally, the associated pain and discomfort can significantly impact a patient’s quality of life, leading to further health complications and increased healthcare costs.

Similarly, sleep apnea, once diagnosed, is often not treated due to the limitations of current therapy options. Patients often need to trade in comfort for therapy effectiveness, and acrylic devices with bars and screws not only show higher failure rates but are also not sustainable. Although continuous airway pressure (CPAP) therapy is clinically effective, up to 50 percent of patients discontinue its use within the first year due to discomfort, claustrophobia, skin irritation, device noise, and difficulties in maintaining the device in place during sleep.

Solution

Ortoplus has developed a state-of-the-art solution using Polyamide 12 and the FORMIGA P 110 Velocis, ensuring repeatable results at scale. It all starts with a patient's dentition record. Silicone trays must be digitized by scanning. Digital data collected using intraoral scanners can be directly subjected to a quality check. Based on this verified data, the devices are designed, 3D printed and post-processed. Once they have a very smooth finish, they undergo a final quality check to ensure that the devices are in optimal condition for delivery.

This workflow ensures the production of highly durable, biocompatible, and comfortable occlusal splints and mandibular advancement devices tailored to each patient's unique anatomy. The precision of 3D printing allows for the creation of customized solutions with high dimensional accuracy and homogenous material properties. PA 12 not only reduces the risk of allergic reactions and irritations due to metal parts, it’s also resistant to chemical degradation and mechanical wear, ensuring its durability in contact with body tissues, thus maximizing treatment efficacy. Since it can be sterilized using autoclaving and gamma radiation, it supports medical professionals in complying with the most stringent medical safety standards.

Thanks to the FORMIGA P110 Velocis and its ability to produce parts with complex geometries at scale, medical professionals are now able to promise patients a comfortable fit – all while shortening waiting periods. Even under continuous use and mechanical stress, PA 12 isn’t as susceptible to deformation as acrylic, and it also makes for a more ecologically friendly solution. Jesús García Urbano, CEO at Ortoplus concludes: "Thanks to the advanced 3D printing technology, we've reduced our production time significantly, which means patients get their custom devices faster than ever."

Results

Since the implementation of customized occlusal splints and MADs made with PA 12 and EOS 3D printing technology, Ortoplus has observed significant improvements in the quality of life for patients suffering from bruxism and sleep apnea. To date, their product OrthoApnea alone has helped 75,000 sleep apnea patients alleviate their symptoms. Ortoplus achieved this through the production of personalized medical devices with repeated high-quality. The Orthoapnea solution has been approved as a medical device under several major regulatory frameworks, including the FDA in the USA, MDD in the EU, MDEL in Canada, and TGA in Australia.

Compared to traditional manufacturing, 3D printing allowed triple production capacity with more repeatable and precise output quality – all without the need for new personnel. Being able to design devices digitally significantly reduced the risk of human error in production while further expanding design possibilities. The devices also demonstrated high dimensional accuracy of less than ±0.1mm, which significantly improved the fit and comfort of splints, contributing to the overall patient satisfaction and treatment efficacy. "Without the reliable results that Polyamide 12 delivers, we simply couldn’t do what we do. We looked at dozens of solutions in the market, none of which adhered to medical standards while allowing for an individualized fit like EOS 3D printing technology." Jesús García Urbano, CEO, Ortoplus.

„Without the reliable results that Polyamide 12 delivers, we simply couldn’t do what we do. We looked at dozens of solutions in the market, none of which adhered to medical standards while allowing for an individualized fit like EOS 3D printing technology."

Jesús García Urbano | CEO Ortoplus