How Do You 3D Print Dental Models?
To 3D print dental models, import and validate the STL file in Rapid Shape Print Studio, select the correct model application profile, and orient the model flat on the build platform with a slight tilt for drainage. Add minimal supports only where needed, verify resin and reservoir, and send to print. After printing, wash using the validated WASH workflow, dry completely, then cure with the CURE unit per the material protocol. Finish by removing supports, inspecting dimensional accuracy, and checking fit against the original scan. Dental models are often produced alongside other restorations — see our guide on crown and bridge 3D printing for a related workflow.
Receiving & Inspecting STL Files in a Digital Dental Workflow
Every print begins with an STL design. These files can be generated in-house (using software like exocad, 3Shape, or Medit), received from external designers, or even created through AI-driven platforms.
Before Importing
- Ensure files are watertight (no open edges).
- Confirm units are in millimeters.
- Verify minimum wall thickness per application.
Pro Tip: Turn on Auto-Repair Before Nesting
Activate “Auto repair non-manifold surfaces on import” so Print Studio automatically corrects STL errors during import.
A clean and validated STL file ensures smooth nesting, stable printing conditions, and optimal dimensional accuracy, all critical for high-precision dental model 3D printing.
Print Preparation for Dental Model 3D Printing in Print Studio
Print Studio is the central software for preparing dental 3D prints, arranging, orienting, and supporting STL files before sending them to the printer.
Key Features
- Compatible with .STL files
- Automatic and manual support generation
- Advanced nesting tools to maximize platform space and resin efficiency
- Built-in RS VIVO resin profiles with validated print parameters
A clean and validated STL file ensures smooth nesting, stable printing conditions, and optimal dimensional accuracy, all critical for high-precision dental model 3D printing.
What is Nesting?
Nesting is the process of arranging one or multiple parts on the build platform in the most efficient and stable way.
The goal is to:
- Maximize platform capacity
- Reduce resin consumption
- Improve print stability
- Maintain dimensional accuracy
- Ensure predictable clinical results
This step includes positioning and orienting each model correctly, applying supports when necessary, and organizing the overall layout, so every part prints accurately and reliably within the dental lab workflow.
Step 1: Select the type of dental application
In this step, the user chooses the correct dental application category for the imported STL file.
Note: This classification helps Print Studio apply the appropriate default settings, specifically loading the supports and baseplate options for the selected workflow.
Orientation & Supports, Optimizing Dental Model Accuracy
Once your STL file is imported and validated, the next step is nesting preparation.
This process directly influences dental model accuracy, surface quality, and post-processing effort. It includes two essential stages:
- Orientation: positioning the model for optimal precision and resin flow
- Supports: ensuring mechanical stability during layer-by-layer fabrication
Together, these steps define how successfully your dental 3D print will perform and how much finishing work will be required.
Step 1: Orientation, Positioning for Best Results
Orientation means adjusting the angle and position of your model on the build platform.
In dental printing, even small rotations (10–20°) can make a big difference in accuracy and print success.
The right orientation ensures:
- Better dimensional accuracy (fit and margins)
- Smooth surface finish (especially on critical areas)
- Fewer print failures or suction effects
- Easy resin drainage
- Efficient use of supports
Think of orientation as deciding how your print grows inside the printer.
Orientation Guidelines per Application
Each application requires different orientation, support, and resin to achieve the best clinical and aesthetic outcomes.
- Solid Models (Orthodontic or Study Models)
- Perfect for orthodontic models or study casts.
- Keep flat on the build platform.
Tilt models at approximately 20–30° to reduce suction and improve print accuracy, especially when printing on platforms without holes or with a completely closed surface.
Maintaining a flat orientation is preferable, but to increase the capacity of the print models, tilt backward between 65° and 75°.
Hollow Models:
- Hollow models reduce internal volume to save resin and printing time.
- They often have internal cavities that require proper drainage.
- Ensure wall thickness of at least 2–3 mm for structural stability.
Flat for single prints; if printing multiple models, a 65–75° tilt helps resin circulation.
Models with Drain Holes:
Always place these models flat on the platform, as the drainage holes allow resin to drain from the model during the printing process. They also facilitate ventilation, which prevents damage or reduced quality in the result.
Step 2: Supports, Stability for Precision Dental Printing
After orientation, it’s time to create supports.
Supports act like temporary scaffolding, holding your model in place as each layer is built. In Print Studio, support can be removed or added manually if required by the design.
Adding Supports in Print Studio
- Use supports under the base and edges.
- Place them under the base only if tilted.
- Avoid occlusal surfaces or critical anatomy parts.
- For drain holes base and lower edges only; do not block drain holes.
When selecting the Dental Model application type in Print Studio, models are loaded without supports by default. If you need to add supports (for example, when printing at an angle or vertically), follow these steps:
1. Click on your STL file → In the dropdown menu, locate the Support option.
2. Press “On” to activate supports.
3. You can then adjust parameters such as Lift and Support Style. Recommended Lift: 3.00 mm
4. For Manual Edit → Select Supports edit mode.
Baseplate Activation
Don’t forget to enable a Baseplate as well:
- In the same dropdown menu for your file, find Baseplate (located below Support). Click On
- Choose your preferred baseplate style, such as:
Easy Removal , recommended for dental models.
- Preview the layout before saving your setup
Common Support Mistakes in Dental 3D Printing
Do’s and Don’ts
Do:
Do keep holes clear to allow proper resin flow.
Do place supports only on outer surfaces.
Do use small tips and lower-density supports.
Do add evenly spaced supports under each unit.
Don’t:
Don’t place supports inside drain holes.
Don’t place supports inside drill holes.
Don’t use oversized supports on thin walls.
Don’t leave long bridges unsupported.
Print Preparation , Ensuring Material and Workflow Accuracy
Before starting a print, confirm that your printer and material are correctly selected in Print Studio.
Make sure the reservoir is clean, properly filled, and thoroughly mixed. If the resin has been idle, gently stir it with the provided rubber spatula or shake the bottle before refilling to maintain a uniform mixture. Additionally, check that the build platform is securely installed and clean to ensure proper adhesion.
Verify that the reservoir and resin combination are correctly identified before printing. While the printer’s RFID recognition system can automatically verify the material profile for compatible resins, this feature is optional. For resins without RFID tags, ensure the material profile is manually assigned in the software to guarantee correct exposure settings and avoid print defects.
When switching between resin types, clean the reservoir with isopropyl alcohol (IPA) and a lint-free cloth to prevent contamination. To optimize your workflow and avoid cross-contamination, it is recommended to use a separate reservoir for each type of resin.
Pro Tip: Support Removal Before Post-Curing
For best results, remove the supports before post-curing, while the material is still slightly soft, as this minimizes surface marks and facilitates removal.
Want to see this workflow on a Rapid Shape printer?
Post-Processing Dental 3D Prints, WASH and CURE
After printing, every part goes through two essential post-processing steps: WASH and CURE.
These stages are critical for ensuring the printed part achieves the proper mechanical strength, dimensional accuracy, and biocompatibility. Skipping or shortening either process can affect the final quality of your dental device, so it’s worth doing it right.
Step 1: WASH, Precision Cleaning for Dental 3D Printing
The WASH unit is an automated cleaning system designed for professional dental 3D prints.
It uses a validated process to remove uncured resin safely and efficiently, ensuring your parts are perfectly clean before curing.
Why Cleaning Matters
Cleaning is not just a cosmetic step, it directly affects:
- Biocompatibility
- Surface finish
- Marginal fit
- UV curing efficiency
How It Works
The WASH connects directly to your printer and automatically detects the resin type to select the correct cleaning cycle.
It typically uses Isopropyl Alcohol (IPA) or Ethanol as cleaning agents, depending on the resin requirements.
Note:
IPA (Isopropyl Alcohol) is a solvent used to dissolve and remove excess liquid resin after printing. It evaporates quickly and leaves no residue.
Recommended Washing Workflow
- Remove your printed parts carefully from the build platform.
- Remove the supports manually while the material is still slightly soft, as this minimizes marks on the surface and facilitates removal.
- Place them into the WASH basket and position the model with the part where the supports were located on the washing chamber.
- The machine will automatically load the proper cleaning program based on your selection from over 200 validated materials. This seamless synchronization is available whenever intelligent connectivity is enabled.
- Cleaning runs in two stages: pre-clean and final clean, usually 6–8 minutes total.
- Ensure that the part is completely dry before curing.
Do’s and Don’ts
Do:
Do use validated cleaning programs for each RS VIVO resin.
Check the fill levels of the IPA bottles located on the side of the unit to ensure a proper cleaning cycle.
Do allow adequate drying time before curing.
Don’t:
Don’t use unapproved cleaning agents or mix solvents.
Don’t shorten the cleaning cycle, resin residue may remain.
Don’t place parts in the curing unit while still wet.
Step 2: CURE – Final Polymerization for Strength and Stability
The CURE unit finalizes the printing process by exposing parts to calibrated UV light and, in some models, vacuum technology for optimal polymerization.
Why Proper Curing Matters
Curing transforms the material from its “green” (soft) state into its fully hardened, biocompatible form.
Without proper curing:
- Mechanical properties are weaker.
- Fit accuracy can shift as the resin continues to shrink.
- Biocompatibility may not meet medical standards.
Recommended Curing Workflow
After cleaning and drying:
- Place the parts inside the CURE chamber.
- The machine will automatically load the proper curing program for the selected resin. By leveraging intelligent connectivity, the unit synchronizes the specific parameters for any of the 200+ validated materials in the library.
- The unit exposes your parts from all directions (360°) for 6–10 minutes, depending on the material.
- Models with vacuum remove oxygen to ensure complete polymerization and avoid surface tackiness.
Do’s and Don’ts
Do:
Do cure parts completely according to RS VIVO resin instructions.
Do ensure parts are fully dry before curing.
Do confirm that the correct resin profile is selected (auto-detected in RS CURE).
Do handle parts carefully after curing, they will be fully hardened but may still be warm.
Don’t:
Don’t skip the curing cycle or shorten it.
Don’t cure parts partially or rely on sunlight , results will be uneven and unpredictable.
Pro Tip: Automated Workflow, Smart and Simple
Your WASH and CURE systems are fully integrated with your Rapid Shape printer.
This means once you select your resin type in Print Studio, the machines automatically:
- Identify the material.
- Load the correct cleaning and curing profiles.
- And notify you when each process is done.
No guessing, no manual setup, just consistent, validated results every time.
This automation helps new digital dental users feel confident and saves time in busy lab environments.
Conclusion: Mastering Dental Model 3D Printing in Modern Dentistry
Dental model 3D printing is more than a technical process, it is a foundational element of digital dentistry and modern dental laboratory production.
By mastering:
- STL validation
- Orientation and support strategy
- Resin handling
- Washing and curing protocols
- Automated workflow integration
Dental professionals ensure accuracy, efficiency, and clinical reliability in every printed model.
A structured, validated workflow transforms additive manufacturing into a predictable and scalable solution for dental practices and laboratories globally.
Frequently Asked Questions About Dental Model 3D Printing
How should I orient dental models for 3D printing?
Orientation depends on the model type. Solid orthodontic models should be kept flat on the build platform for best dimensional accuracy. When printing multiple models, tilt them 65–75° to maximize platform capacity. For platforms with a closed surface, a 20–30° tilt reduces suction effects and improves print stability. Models with drain holes should always be printed flat to allow proper resin drainage.
Do dental models need supports in Print Studio?
Before importing into Print Studio, confirm the file is watertight (no open edges) and that units are set to millimeters. Enable the “Auto repair non-manifold surfaces on import” option so Print Studio automatically corrects geometry errors during import. A clean, validated STL ensures stable nesting, accurate printing, and consistent clinical results.
How do I prepare an STL file for dental model 3D printing?
Before importing into Print Studio, confirm the file is watertight (no open edges) and that units are set to millimeters. Enable the “Auto repair non-manifold surfaces on import” option so Print Studio automatically corrects geometry errors during import. A clean, validated STL ensures stable nesting, accurate printing, and consistent clinical results.
How long does washing and curing take for dental 3D prints?
Washing runs in two stages, pre-clean and final clean, with a total duration of around 6–8 minutes. Once the parts are completely dry, they move to the CURE unit, which exposes them to 360° calibrated UV light for 6–10 minutes depending on the material. Both machines automatically load the correct program based on the selected resin, so no manual configuration is needed.
What happens if dental 3D printed parts are not properly washed or cured?
Insufficient washing leaves uncured resin residue that compromises surface finish, marginal fit, and biocompatibility. Incomplete curing leaves the material in a “green” state, mechanically weak, dimensionally unstable due to continued resin shrinkage, and potentially non-compliant with medical biocompatibility standards. Neither step should be shortened or skipped.
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