3D Printing in Dentistry

Ather Hashir
BIO CARE, Pearl City, Multan, Pakistan
Correspondence to: hashirather2002@gmail.com

DOI: https://doi.org/10.70389/PJD.100003

Additional information

• Ethical approval: N/a
• Consent: N/a
• Funding: No industry funding
• Conflicts of interest: N/a
• Author contribution: Hashir Ather – Conceptualization, Writing – original draft, review and editing
• Guarantor: Hashir Ather
• Provenance and peer-review:
  Commissioned and externally peer-reviewed
• Data availability statement: N/a

Keywords: 3D printing in dentistry, Biocompatible dental materials, CAD, CAM technology, Digital dental workflows, Personalized dental prosthetics.

Peer Review
Received: 28 January 2025
Revised: 20 March 2025
Accepted: 22 March 2025
Published: 10 April 2025

Introduction

In recent years, dentistry has encountered innovations in terms of technology and materials science. By replacing traditional craftsmanship, digital workflows have significantly enhanced precision, efficiency, and patient comfort. Modifications in orthodontic and prosthodontic treatments have been observed since modern dentistry came into being in the form of computer-aided manufacturing/computer-aided design (CAD/CAM) and 3D printing.¹ Improvements in the digital design of dental prostheses have been made possible by CAD/CAM technology. This has made the procedure of crafting a dental prosthesis more efficient and accurate than conventional methods. Predictable treatment outcomes were made possible due to reduced human error and increased fit and aesthetics of dentures.² CAD/CAM technology does not require any patient molds, which has improved patient comfort to a great extent.³

3D printing has changed the dynamics of dentistry by introducing cost-effective and rapid production of dental models, aligners, surgical guides, and biocompatible prosthetic components.⁴ Treatment options have become customized, which in turn has advanced personalized oral healthcare.⁵ Personalized dental implants and tissue engineering are inventions of bioprinting, which have introduced new possibilities in regenerative dentistry.⁶ However, such modern technology comes with limitations like those found in terms of production cost and steep learning. They occur as an obstacle to widespread adoption. Research is being undertaken to make this technology applicable for long-term use.⁷ It is important to address such concerns in order to make full use of this technology. Reduction in chairside time, optimization of resources, and creation of more durable and aesthetic restorations are the advancements introduced by the integration of 3D printing in dentistry.⁸ These advancements have completed the objectives of minimally invasive dentistry along with preserving natural tooth structures.⁹ The future of dentistry is shaped to a great extent, thanks to the integration of cutting-edge technologies. Modern technology has not only provided more successful treatments but has also reinforced the importance of continuous technological progress in the field (Figure 1).¹⁰

History

3D printing was introduced in the world of dentistry in the early 1900s. This technology was used to produce dental models and surgical guides.¹¹ Such models provide a realistic image of a patient’s oral cavity, which has become useful for physicians. An improvement in surgical outcomes and treatment planning was observed because of this. 3D printing has reduced the difficulty level of doing complex dental procedures to a great extent. It has reduced the margin for error and has increased the level of satisfaction among patients. Metal-based printing materials and biocompatible resins have paved the way for developments in dental 3D printing. With such advancements, it is easier to construct permanent dental restorations like crowns, bridges, and implants in no time.¹² Enhancements in biocompatibility and durability of dental prostheses have produced wonders. The introduction of CAD/CAM and its synergy with 3D printing has popularized dentistry to a great extent.¹³ It has undoubtedly introduced modern dentistry to the world. Such advancements have revolutionized the characteristics of dental procedures and have made them more accurate and efficient.

The dental sector has been affected positively by a strong synergy of 3D printing and CAD/CAM technology. A precise 3D picture of a patient’s dentition can be taken in no time, thanks to CAD/CAM technology. This 3D picture can be given to design a required prosthesis with the help of a 3D printer. This has led to a well-constructed prosthesis that meets the patient’s anatomical landmarks. Human error has been reduced, and more accurate dental restoration can be performed with this technology. This has led to a more effective, economical, and readily available dental procedure, thereby modernizing dental procedures to a great extent. Patient specificity in dental procedures is a great wonder introduced by 3D printing. Additionally, same-day restorations and customized orthodontic devices offer significant benefits to patients. Now, it is easy to make restorations, like crowns and veneers on-site in dental offices.¹⁴ Patient visits have undergone a reduction thanks to this. It has brought convenience to patients. Technology has improved orthodontics by introducing customized retainers and clear aligners. Such innovations have benefited both patients and dental practitioners to a great extent.

An improvement in dental treatment outcomes is observed by integrating CAD/CAM technology. This is because of the ongoing progress in material science and software capabilities. Biofabrication and multi-material printing are new concepts introduced by modern dentistry.¹⁵ Such concepts have paved the way for more advanced dental solutions like tissue engineering and personalized dental implants. An increase in success rates and patient experiences is also observed by the integration of new technology with dental care, as precision, effectiveness, and accessibility of dental care are enhanced to a great extent (Figure 2).¹⁶

Conceptualization of 3D Printing and Its Implementation

One can say that 3D printing has fulfilled the demand for a more effective, accurate, and economical method to produce dental restorations. Even if outdated methods were effective, they are no match to 3D printing or new modern technology in terms of time management. These methods required numerous patient visits and manual adjustments. However, modern technology helps in finishing a dental in a short time span, with more accuracy and precision. Digital fabrication has evolved dentistry by introducing simplified dental procedures.¹⁷ They have ousted the conventional method by producing a more reliable method in a short time span and with fewer patient visits.

3D printing has brought realities to dentistry by introducing more advanced dental hardware, software, and materials. Biocompatible photopolymers and ceramic-based composites are advancements in resin-based material brought by modern dentistry.¹⁸ Such advancements have increased the range of printed dental applications. Dental restorations like crowns, bridges, etc., have attained increased longevity thanks to such advancements.¹⁹ Top dental firms have brought advancements in 3D printing systems. Advanced printers and dental materials have been introduced to the market due to collaboration between dental professionals, IT firms, and academic institutions. The evolution of the concept of tissue-engineered restorations and customized implants is being studied thoroughly to provide more advanced dental procedures to patients (Figure 3).

Design procedures and personalization are improved by 3D modeling and scanning software, which has improved dental procedures.4 3D printing has brought the concept of in-office manufacturing, which has saved dental professionals time and has made dental procedures less time-consuming to a great extent. Decreases in such turnaround times have enhanced patient happiness and satisfaction scale. Formlabs, Stratasys, and 3D Systems are top dental firms that have provided advancements in the field of dentistry by introducing 3D printing technology.²⁰ Furthermore, bioprinting research has paved the way for modern dentistry in terms of bone graft materials and artificial gum tissues. They have impacted periodontal care positively. Stem cell technology and bioinks have produced patient-specific tissues that can blend with the natural colors of the oral cavity. Modern technology has improvised the implant procedure and bone grafting methods to a great extent. They have enhanced success rate of such procedures.

3D printing has improved the precision of dental procedures by attaining control over the microarchitecture of tissues being produced. This has increased success rates by improving the durability, biocompatibility, and strength of such artificial tissues. Functional oral tissues are being produced that have attained maximum functionality and match the aesthetics of the mouth to a great extent, making their use successful.²¹ The range of treatment plans has also increased due to the integration of 3D printing in dentistry. This is because of the use of new materials that have enhanced durability and biocompatibility, thereby allowing revolutionary developments in the field of dentistry. AI-driven design optimization and automation have enhanced treatment plans, as they have reduced costs and increased accessibility.²² Cloud-based technologies have done wonders by introducing more advanced dental restorations, which have been produced by collaboration between dental practitioners and laboratories.²³

Pros and Cons

Advantages

Enhanced Precision and Accuracy in Dental Procedures

3D printing has customized dental appliances and restorations. They are more precise in terms of fitting and have enhanced functionality. On the other hand, traditional methods used to produce dental prosthetics often require multiple adjustments, which in turn increases treatment time and discomfort for the patients. 3D printing has enhanced the precision of dental impressions and fabrications to a great extent. In short, 3D printing has made the fitting of dental appliances more efficient, which has reduced the need for modifications.²⁴ In the case of prosthetics and implants, reduction in error can only be attained by fabricating highly accurate dental models. This has been made possible by the introduction of 3D printing in dentistry. An exact replica of a patient’s oral structures can be generated with the use of 3D scanning and digital workflows. Enhancements in the effectiveness of many dental treatments, such as dental crowns, bridges, and dentures, have been made possible by integrating 3D printing, leading to better long-term outcomes.²⁵ Improvements in 3D printing in terms of precision have enhanced patient comfort and treatment outcomes. It has reduced the need for modifications and remakes. Nowadays, fewer complaints have been received by patients regarding ill-fitting dental restorations. The success rate in treatments has been increased because of this. Function and aesthetics of dental prosthesis have been increased as an accurate prosthesis made by 3D printing looks more natural and more aesthetically pleasing.

Time and Cost Efficiency in Dental Practices

With the integration of 3D printing in dentistry, patients now experience shorter wait times. Dental implants, crowns, and orthodontic devices can be constructed efficiently, and their procedural time has been reduced to a great extent. This technology has surpassed the conventional methods, which require a multiple-step approach and outsourcing. A convenient environment is established for both patients and dentists, as this technology has made possible the construction of dental restorations in a single visit. In dental clinics, operational costs and labor-intensive tasks have been reduced due to digital workflows. Reliance on extensive manual labor is now a thing of the past, as design automation and additive manufacturing processes have changed the fate of modern dentistry. This evolution in efficiency has made dentists able to focus more on patient care rather than the production of dental restorations.

Among all the wonders of 3D printing, reduction in material wastage is of prime importance as well. 3D printing has introduced additive manufacturing to the field of dentistry, which has reduced wasting of materials and made more cost-effective treatments. This is because, in 3D printing, dental restorations are made layer by layer, and only the necessary amount of material is used.²⁶ This is not found in traditional methods, in which restorations are made by carving solid blocks of material. Such optimization introduced by 3D printing has introduced more economical and resource-efficient dental care. However, challenges persist in standardization, reproducibility, and long-term clinical validation of 3D-printed dental restorations. Variable materials can affect treatment predictability to a great extent. Furthermore, there is no universally accepted manufacturing protocol that implements a significant hurdle. There are concerns that need to be addressed regarding post-processing complexities and quality control. Such concerns are of utmost importance in terms of the widespread adoption of this technology.

Revolutionizing Patient Care with Personalization

Effective treatment has been made possible by integrating 3D printing, which has provided tailored solutions to match unique patient anatomy. Traditional methods cannot fulfill individual needs, as each patient has distinct oral structures and traditional methods involve standardization. Precise conformation to the patient’s morphology in terms of customization of prosthetics, aligners and implants has been made possible by use of 3D printing. 3D printing has made improvements in patient planning and execution by providing custom prosthodontics, orthodontics, and surgical guides. This technology has so far provided improvements in efficiency and success rates of procedures by introducing personalized designs. Such level of customization has enhanced functional outcomes along with patient satisfaction. Patient care has become more personalized, thanks to 3D printing. This technology provides digital prototypes, which can be studied and assessed by both patient and dental practitioners. The integration of CAD/CAM with 3D printing has made this possible.²⁷ It has improved decision making, increased trust between patient and dental practitioner, as transparency is established by utilizing this modern technology.

Challenges and Limitations

High Initial Cost and Maintenance of Equipment

3D printing undoubtedly increases the success rate of various dental procedures. However, a huge investment is required to make this technology a tool for completing dental procedures. Many dental clinics, whether small- or medium-sized, have to face this financial burden. To make sure that 3D printers are being used effectively, the required software and material must be available, which is costly.²⁸ Maintaining such devices is also challenging. Software updates and material refills are also a burden to the financial budget of any uprising dental clinic. Furthermore, 3D printers have different requirements for their optimal performance. These include cleaning and calibration. The maintenance protocols for 3D printers are mandatory. Without following such protocols, the accuracy and reliability of dental restorations produced by printers could be compromised. This has a negative effect on patient outcomes. In addition, replacement parts of such printers are costly, and for many dental clinics, they are not bearable. Also, not everyone is well-trained to handle such devices properly. Therefore, a well-trained and skillful staff is required as well. This can be achieved by proper education and skill development. For sustainable use of 3D printing technology, environmental considerations must be addressed, such as proper disposal of used materials and energy consumption. Such environmental considerations are mandatory. However, appropriate management and investment in maintenance and training protocols is required to ensure the efficiency and precision of a 3D printer.

Material Limitations and Biocompatibility Concerns

A limited variety of dental-grade materials are suitable for different applications in the field of dentistry. Some materials are durable, while others are not. Some materials are excellent in terms of aesthetics, others are not. Many procedures have a limited range because of this, and as a result, they cannot benefit from 3D printing to a great extent. For example, in molar restorations, not all materials are suitable to bear high-load masticatory forces, and therefore, such materials are limited to anterior teeth. Another major concern is of biocompatibility. Strict regulatory protocols are implemented while dental materials are selected for 3D printing. This is done to ensure patient safety. Achieving certification and regulatory approval for new materials is a lengthy and expensive process.²⁹ This, in turn, affects the development and adoption of innovative materials. A complication is found by manufacturers while introducing a dental material, i.e., different countries have different regulatory protocols. This complicates the process and creates more challenges when introducing a new material to the market. Furthermore, prolonged clinical trials and biocompatibility testing induce delays in advancements in material science.

In addition, the long-term performance of such materials is questioned. Many factors contribute to the long-term performance of such materials. These include wear resistance, color stability, and resistance to bacterial adhesion.³⁰ A thorough evaluation of these factors is required to ensure the longevity of dental restorations. Issues of discoloration and reduced mechanical strength over time have been reported by early adopters of 3D-printed dental materials. Such issues have highlighted the fact that there is still room available for future refinement of these dental materials in order to achieve better treatment outcomes. Thorough research is being conducted focusing on advanced composites and hybrid materials. These research efforts come with a vision to enhance the durability and functionality of printed dental prosthetics. Despite limitations in the materials required for dental procedures, innovation can be driven by research and collaboration between material scientists, dental professionals, and manufacturers. Furthermore, next-generation dental materials are more likely to have superior mechanical properties and biocompatibility. This is due to advancements in nanotechnology and polymer chemistry. Such advancements are more likely to expand the adoption of 3D printing in dentistry to a great extent, thereby providing more long-lasting and reliable solutions for patients.

Steep Learning Curve and Technical Expertise

Several challenges arise while maintaining and operating a 3D printer. Such challenges require special attention. To make sure that the printer shows peak performance and enhanced functionality, regular calibration, cleaning, and troubleshooting must be done. If such things are not done on time, then there is a chance of many issues. These issues include misalignment, material contamination, and software malfunctions.³¹ They can lead to inaccuracies in printed dental restorations. In the worst-case scenario, such inaccuracies pave the way for compromising the fit, strength, and overall quality of dental prosthetics, which in turn affects patient outcomes. Material waste, equipment downtime, and the need for reprints can lead to a rise in operational costs, which occurs if routine maintenance is neglected. Additionally, staff training is also very important for enhanced efficiency of dental 3D printers. This can only be achieved if a proper maintenance schedule is followed, along with continuous technical education given to dental professionals. It can reduce risks, thereby enhancing the reliability of 3D printers, along with making a cost-effective tool in modern dental practices.

Conclusion

One cannot deny the fact that 3D printing has transformed the field of dentistry into what it is now. The functionality and aesthetics of dental care have been revolutionized by this technology. The construction of dental restorations has been improved in terms of accuracy and functionality. Apart from this, an improvement in patient time and treatment satisfaction is also observed. Such improvements have cleared the road toward biocompatible materials and regenerative applications. However, many concerns arose when this technology became applicable. Scalability and cost-effectiveness are issues that need to be addressed. Also, smaller clinics or dental setups cannot bear the financial burden imposed by this technology as well. Acquiring 3D printing comes with a high maintenance cost, and this has made such technology unable to be used in smaller dental practices, thereby limiting its acceptability. Clinician training, software advancements, and integration are essential for the smooth operation of this technology, and they cannot be done if a person does not meet the necessary requirements. In order to maximize the potential of 3D printing, it is mandatory to make advancements in materials, software integration, and training of clinicians. 3D printing has undoubtedly revolutionized the field of dentistry, but its widespread acceptability can only be attained if concerns regarding its cost and expertise are dealt with great concerns. If such concerns are dealt with thoroughly, then this technology can do more wonders than it is doing nowadays.

References

1 Dobrzański LA, Dobrzański LB, Dobrzańska-Danikiewicz AD, Dobrzańska J. The concept of sustainable development of modern dentistry. Processes. 2020;8(12):1605.
https://doi.org/10.3390/pr8121605
 
2 Dawood A, Marti BM, Sauret-Jackson V, Darwood A. 3D printing in dentistry. Br Dent J. 2015;219(11):521-9.
https://doi.org/10.1038/sj.bdj.2015.914
 
3 Davidowitz G, Kotick PG. The use of CAD/CAM in dentistry. Den Clin N Am. 2011;55(3):559-70, ix.
https://doi.org/10.1016/j.cden.2011.02.011
 
4 Beuer F, Schweiger J, Edelhoff D. Digital dentistry: An overview of recent developments for CAD/CAM generated restorations. Br Dent J. 2008;204(9):505-11.
https://doi.org/10.1038/sj.bdj.2008.350
 
5 Susic I, Travar M, Susic M. The application of CAD/CAM technology in dentistry. In IOP Conference Series: Materials Science and Engineering 2017;(Vol. 200, No. 1, p. 012020). IOP Publishing.
https://doi.org/10.1088/1757-899X/200/1/012020
 
6 Samra AP, Morais E, Mazur RF, Vieira SR, Rached RN. CAD/CAM in dentistry-A critical review. Rev Odonto Ciência. 2016;31(3):140-4.
https://doi.org/10.15448/1980-6523.2016.3.21002
 
7 Kessler A, Hickel R, Reymus M. 3D printing in dentistry-State of the art. Oper Dent. 2020;45(1):30-40.
https://doi.org/10.2341/18-229-L
 
8 Zaharia C, Gabor AG, Gavrilovici A, Stan AT, Idorasi L, Sinescu C, et al. Digital dentistry-3D printing applications. J Interdiscip Med. 2017;2(1):50-3.
https://doi.org/10.1515/jim-2017-0032
 
9 Shujaat S, Bornstein MM, Price JB, Jacobs R. Integration of imaging modalities in digital dental workflows-possibilities, limitations, and potential future developments. Dentomaxillofac Radiol. 2021;50(7):20210268.
https://doi.org/10.1259/dmfr.20210268
 
10 Vasamsetty P, Pss T, Kukkala D, Singamshetty M, Gajula S. 3D printing in dentistry-Exploring the new horizons. Mater Today Proc. 2020;26:838-41.
https://doi.org/10.1016/j.matpr.2020.01.049
 
11 Kalra M, Aparna IN, Dhanasekar B. Evolution of surgical guidance in implant dentistry. Dent Update. 2013;40(7):577-82.
https://doi.org/10.12968/denu.2013.40.7.577
 
12 Espinar C, Della Bona A, Pérez MM, Tejada-Casado M, Pulgar R. The influence of printing angle on color and translucency of 3D printed resins for dental restorations. Dent Mater. 2023;39(4):410-7.
https://doi.org/10.1016/j.dental.2023.03.011
 
13 Suganna M, Kausher H, Ahmed ST, Alharbi HS, Alsubaie BF, Aruna DS, et al. Contemporary evidence of CAD-CAM in dentistry: A systematic review. Cureus. 2022;14(11):e31687.
https://doi.org/10.7759/cureus.31687
 
14 Shaikh S, Nahar P, Ali HM. Current perspectives of 3D printing in dental applications. Brazil Dent Sci. 2021;24(3). https://doi.org/10.14295/bds.2021.v24i3.2481
https://doi.org/10.14295/bds.2021.v24i3.2481
 
15 Rahimnejad M, Makkar H, Dal-Fabbro R, Malda J, Sriram G, Bottino MC. Biofabrication strategies for oral soft tissue regeneration. Adv Healthc Mater. 2024;13(18):e2304537.
https://doi.org/10.1002/adhm.202304537
 
16 Ohara K, Isshiki Y, Hoshi N, Ohno A, Kawanishi N, Nagashima S, et al. Patient satisfaction with conventional dentures vs. digital dentures fabricated using 3D-printing: A randomized crossover trial. J Prosthodont Res. 2022;66(4):623-9.
https://doi.org/10.2186/jpr.JPR_D_21_00048
 
17 Abdel-Azim T, Zandinejad A, Elathamna E, Lin W, Morton D. The influence of digital fabrication options on the accuracy of dental implant-based single units and complete-arch frameworks. Int J Oral Maxillofac Implants. 2014;29(6):1281-8.
https://doi.org/10.11607/jomi.3577
 
18 Zandparsa R. Digital imaging and fabrication. Dent Clin. 2014;58(1):135-58.
https://doi.org/10.1016/j.cden.2013.09.012
 
19 Sulaiman TA. Materials in digital dentistry-A review. J Esthet Restor Dent. 2020;32(2):171-81.
https://doi.org/10.1111/jerd.12566
 
20 Alageel O. Three-dimensional printing technologies for dental prosthesis: A review. Rapid Prototyp J. 2022;28(9):1764-78.
https://doi.org/10.1108/RPJ-07-2021-0164
 
21 Javed R, Rais F, Fatima H, ul Haq I, Kaleem M, Naz SS, et al. Chitosan encapsulated ZnO nanocomposites: Fabrication, characterization, and functionalization of bio-dental approaches. Mater Sci Eng C. 2020;116:111184.
https://doi.org/10.1016/j.msec.2020.111184
 
22 Shan T, Tay FR, Gu L. Application of artificial intelligence in dentistry. J Dent Res. 2021;100(3):232-44.
https://doi.org/10.1177/0022034520969115
 
23 Dhopte A, Bagde H. Smart smile: Revolutionizing dentistry with artificial intelligence. Cureus. 2023;15(6):e41227.
https://doi.org/10.7759/cureus.41227
 
24 Konidena A. 3D printing: Future of dentistry? J Indian Acad Oral Med Radiol. 2016;28(2):109-10.
https://doi.org/10.4103/0972-1363.195081
 
25 Lin L, Fang Y, Liao Y, Chen G, Gao C, Zhu P. 3D printing and digital processing techniques in dentistry: A review of literature. Adv Eng Mater. 2019;21(6):1801013.
https://doi.org/10.1002/adem.201801013
 
26 Jawahar A, Maragathavalli G. Applications of 3D printing in dentistry-A review. J Pharm Sci Res. 2019;11(5):1670-5.
 
27 Fuster-Torres MA, Albalat-Estela S, Alcañiz-Raya M, Peñarrocha-Diago M. CAD/CAM dental systems in implant dentistry: Update. Med Oral Patol Oral Cir Bucal. 2009;14(3):E141-5.
 
28 Martelli N, Serrano C, van den Brink H, Pineau J, Prognon P, Borget I, et al. Advantages and disadvantages of 3-dimensional printing in surgery: A systematic review. Surgery. 2016;159(6):1485-500.
https://doi.org/10.1016/j.surg.2015.12.017
 
29 Scribante A, Gallo S, Pascadopoli M, Canzi P, Marconi S, Montasser MA, et al. Properties of CAD/CAM 3D printing dental materials and their clinical applications in orthodontics: Where are we now? Appl Sci. 2022;12(2):551.
https://doi.org/10.3390/app12020551
 
30 Arcila LV, de Carvalho Ramos N, Bottino MA, Tribst JP. Indications, materials and properties of 3D printing in dentistry: A literature overview. Res Soc Dev. 2020;9(11):e80791110632.
https://doi.org/10.33448/rsd-v9i11.10632
 
31 Azari A, Nikzad S. The evolution of rapid prototyping in dentistry: A review. Rapid Prototyp J. 2009;15(3):216-25.
https://doi.org/10.1108/13552540910961946

Cite this article as:
Hashir A. 3D Printing in Dentistry. Premier Journal of Dentistry 2025;2:100003

Export to EndNote Export to Mendeley