How Do You 3D Print Dental Splints?
To 3D print dental splints, import and validate the STL file in Rapid Shape Print Studio, select the splint application profile, and orient the splint at the build angle recommended for your specific resin, this varies by resin and reservoir, so check its documentation rather than assuming one universal angle. Generate supports, verify your validated resin and reservoir, and start the print. After printing, wash in the WASH unit, then handle support removal and curing in the order specified by your selected resin’s instructions for use, this also varies by material. Finish by smoothing any remaining support marks, polishing as needed, and performing a final fit check before delivery.
This guide covers the complete workflow for 3D printing dental splints (occlusal guards, night guards, and bleaching splints), from STL inspection to surface finishing. Achieving a comfortable, accurate fit requires precise file preparation, the right orientation strategy, and a controlled, validated post-processing sequence.
This guide provides a structured overview of the validated workflow for printing splints, from STL inspection and orientation to material handling, washing, and final curing. By following a standardized digital workflow, dental professionals and laboratories can ensure predictable results and maintain high clinical quality standards in professional additive manufacturing environments.
Ready to start printing? Digital dentistry transforms how you can design and manufacture splints, and we’re here to make the process easy.
Receiving & Inspecting STL Files for Splint 3D Printing
Every splint 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
In Print Studio’s settings, activate “Auto repair non-manifold surfaces on import” so the software automatically corrects STL errors during import.
Print Preparation for Splint 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 Splint Hard and Splint Flex resin profiles, part of an open material platform with additional validated splint resins available, each with validated print parameters
What Is Nesting?
Nesting is the process of arranging one or multiple splints 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 splint 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 splint application profile for the imported STL file.
Note:
This classification helps Print Studio apply the appropriate default settings, specifically loading the supports and baseplate options validated for the selected splint resin.
Orientation & Supports, Optimizing Splint Accuracy
Once your STL file is imported and validated, the next step is nesting preparation. This process directly influences dimensional accuracy, surface quality, and post-processing effort. It includes two essential stages:
- Orientation: positioning the denture components for optimal precision and resin flow
- Supports: ensuring mechanical stability during layer-by-layer fabrication
Together, these steps define how successfully your splint 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 splint on the build platform. Think of orientation as deciding how your print grows inside the printer.
The right orientation ensures:
- Better dimensional accuracy at the occlusal table and border
- Smooth surface finish, especially on functional and visible areas
- Fewer print failures or suction effects
- Easy resin drainage
- Efficient use of supports
Orientation Guidelines for Splints
In general, the ideal build angle for a splint balances two competing factors: how much of the print faces the build platform at a shallow angle, and how much support ends up on the occlusal surface as a result. A shallower angle (closer to occlusal-down) tends to be the fastest single print, but places supports directly on the occlusal table, which then need to be polished off afterward.
A steeper, closer-to-vertical angle keeps the occlusal surface cleaner and can reduce finishing time on that surface, but takes longer to print overall and, on some printers, can risk minor distortion on thin anterior sections if pushed to a perfectly perpendicular position.
In practice, this trade-off splits into two ranges depending on whether Crystal Polish is used. Without Crystal Polish, splint resins are typically printed at a shallower angle, commonly in the range of about 40° to 45°, with supports landing on the occlusal surface that are then polished off afterward. With Crystal Polish, the recommended angle is steeper, typically around 60°, since the dedicated resin vat is what produces the near high-gloss surface directly off the printer, and the steeper angle keeps that finish clean.
Do’s and Don’ts
Do:
Do choose the vertical orientation when minimizing support marks on the occlusal table is the priority.
Do check resin flow paths and avoid creating trapped areas in deep palatal sections.
Do preview supports after orienting, before sending the file to print.
Don’t:
Don’t leave large flat spans of the splint unsupported.
Don’t orient thin border sections facing straight down without support.
Don’t mix orientations within the same build platform without checking that all parts still drain and support correctly.
Step 2: Supports, Stability for Precision Splint Printing
After orientation, it’s time to generate supports. Supports act like temporary scaffolding, holding your splint in place as each layer is built. In Print Studio, supports can be edited manually if the automatic proposal needs adjustment.
Adding and Reviewing Supports in Print Studio
- Provide even, continuous support coverage along the border of the splint, without gaps.
- Space support tips so they do not overlap, overlapping tips fuse into one large support during printing and can leave marks on removal.
- Check in preview mode to confirm even distribution along the entire border, without skipping sections.
Important:
Never allow a support tip to penetrate into a critical fitting or functional surface, this alters the fit and increases finishing time.
Common Support Mistakes in Splint 3D Printing
Do:
Do keep support density even and continuous along the entire border.
Do review the automatically generated supports in Print Studio before printing.
Do add evenly spaced supports rather than clustering them in one area.
Don’t:
Don’t leave large flat, unsupported spans, they are a common source of mid-print distortion.
Don’t rely on a single oversized support for a full arch.
Don’t skip supports on distal extensions, this area is easy to under-support.
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. It is recommended to use a separate reservoir for each type of resin.
Crystal Polish option
Splints printed with a Crystal Polish resin vat and a compatible splint resin come off the printer with a near high-gloss surface. This significantly reduces the amount of manual polishing needed at the finishing stage, while maintaining excellent surface quality.
Post-Processing Dental 3D Prints: WASH and CURE
After printing, every splint 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 affects the final quality and comfort of the device, so it’s worth doing it right.
Before you start, check your connectivity
If the printer, WASH, and CURE are connected and intelligent connectivity has been set up and enabled, selecting your splint resin in Print Studio lets the system identify the material, load the correct cleaning and curing profiles, and notify you when each process is done automatically. If that one-time connection has not been configured yet, you will need to select the resin profile manually on the WASH and CURE units instead. Either way, the steps below are the same, only the amount of manual selection differs.
Step 1: WASH, Precision Cleaning for Splint 3D Printing
The WASH unit is an automated cleaning system designed specifically for professional denture 3D printing post-processing. It uses a validated process to remove uncured resin safely and efficiently, ensuring your denture components are perfectly clean before curing.
Why Cleaning Matters
- Surface finish, especially across the occlusal table
- Tissue surface adaptation
- UV curing efficiency
- Biocompatibility
How It Works
The WASH unit connects directly to your printer and automatically detects the resin type to select the correct cleaning cycle. In denture 3D printing post-processing, 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. Always use the cleaning agent recommended by the resin manufacturer to avoid compromising the surface integrity of the denture.
Recommended Washing Workflow
- Remove your printed splints carefully from the build platform. A short drip time is often recommended before this step, check your resin’s IFU for the exact duration, roughly 10 minutes is common practice for several splint resins.
- Place them into the WASH basket.
- The machine will automatically load the proper cleaning program based on your resin selection from the validated materials library, provided intelligent connectivity is enabled (see note above).
- Cleaning runs in two stages, pre-clean and final clean, typically 6-8 minutes total, depending on the selected resin and its validated material profile.
- Before moving to curing, check openings, cavities, and gap areas for any remaining resin residue, and clear them with compressed air.
- Ensure the part is completely dry and free of IPA residue before placing it in the CURE unit.
Important, this step is resin-specific
Exactly when supports are removed relative to curing is not the same for every splint resin. Some manufacturers specify removing supports after washing, while the part is still slightly soft and easier to detach cleanly, and curing afterward. Others treat support removal as part of the final surface finishing step, after the part is fully cured. Always follow the sequence specified in your selected resin’s own instructions for use rather than assuming one order applies universally.
Do’s and Don’ts
Do:
Do use the validated cleaning program for your selected splint resin.
Do follow your resin’s IFU for exactly when to remove supports relative to curing.
Do allow adequate drying time before curing.
Don’t:
Don’t use unapproved cleaning agents or mix solvents.
Don’t shorten the validated cleaning cycle.
Don’t place parts in the curing unit while they are 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” (partially polymerized) state into its fully hardened, biocompatible final form.
- Mechanical properties are weaker.
- Fit accuracy can shift as the resin continues to shrink.
- Biocompatibility may not meet medical device standards.
Recommended Curing Workflow
After cleaning and drying:
- Place the splints inside the CURE chamber.
- The machine will automatically load the proper curing program for the selected resin, provided intelligent connectivity is enabled (see note above).
- The unit exposes your parts from all directions (360°), typically for 6-10 minutes depending on the selected resin and its validated material profile.
- 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 the selected resin’s validated instructions.
Do ensure parts are fully dry before curing.
Do confirm the correct resin profile is selected.
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.
Don’t insert the splint intraorally unless it is in a fully cured state.
Step 3: Finishing
After WASH and CURE, finish the splint by removing any remaining support structures (if not already removed earlier per your resin’s IFU), smoothing attachment points, and polishing as needed.
- Smooth support attachment points using an appropriate rotary instrument or polisher, working with low contact pressure for a consistent result.
- Inspect the border and occlusal table for any residual marks and polish lightly to achieve a uniform surface.
- If the splint was printed using a Crystal Polish reservoir, this step is typically much faster, since the surface is already near high-gloss straight from the printer.
Frequently Asked Questions About Splint 3D Printing
What STL file requirements are needed before 3D printing a splint?
STL files must be watertight with no open edges, set to millimeter units, and meet the minimum wall thickness required for the specific splint resin and indication. Activating auto-repair for non-manifold surfaces before nesting helps prevent print failures.
How should a splint be oriented for 3D printing?
It depends on whether Crystal Polish is used. Without Crystal Polish, splints are printed at a shallower angle, around 40° to 45°. With Crystal Polish, a steeper angle of around 60° is used to keep the near high-gloss surface clean.
Should supports be removed before or after curing?
This depends on the specific splint resin you are using, it is not the same across all materials. Some manufacturers specify removing supports after washing, while the part is still slightly soft, which can make them easier to detach cleanly, followed by curing. Others specify curing first and treat support removal as part of the final surface finishing step. Always follow the sequence in your selected resin’s own instructions for use rather than assuming one order applies to every splint material.
How long does the WASH and CURE process take for 3D printed splints?
Washing typically runs 6-8 minutes across two stages (pre-clean and final clean), and curing typically runs 6-10 minutes with 360° light exposure, though exact durations depend on the selected resin’s validated material profile rather than being set manually by the user. These programs are loaded automatically whenever intelligent connectivity between the printer, WASH, and CURE is enabled.
What is Crystal Polish and how does it help with splints?
Crystal Polish is a process that uses dedicated resin vats. When paired with a compatible splint resin, it produces a near high-gloss surface directly from the printer, reducing the amount of manual polishing needed at the finishing stage while maintaining excellent surface quality.
Which resins can be used to 3D print splints?
Splints can be printed with RS VIVO Splint Hard or RS VIVO Splint Flex, biocompatible, clear, odorless and tasteless resins with validated print, wash, and cure profiles. As an open material platform, additional third-party splint resins are also validated on specific printer models, always confirm that the resin you select is approved for splint use before printing.
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