3D technologies


3D printers

3D metal printer EOS M100 – DMLS/SLM technology *

The EOS M100 printer is an industrial DMLS / SLM technology in a compact form, dedicated to laboratories and R & D departments. It is the smallest 3D metal printing system which is an excellent solution for the production of unitary products and small series production of small-sized components. The system uses a proven fiber laser (200W), which ensures process stability and production of high-quality parts.

High process parameters enable quick and economical production. In addition, a small laser spot diameter and high resolution allow you to produce complex geometries.The combination of the fiber laser, the new generation of laser exposure parameters and the stabilization system of print parameters ensures the highest quality of production. The density of the elements produced (100%) and their precision fixed by annealing in a special furnace guarantee the full satisfaction of the ordering parties.Our certificates can be treated as the conformation of the high – quality production.

3D Printing Dental technology SLM / DMLS / LaserCusing – laser sinters / sintered metals and SLA – 3D models / light curing resin technology *

Jakość bez kompromisów!!!

Quality without compromise !!!

*DMLS (Direct Metal Laser Sintering) is a name registered byf the German company EOS (Electro Optical Systems). SLM (Selective Laser Melting) is a registered company name of MCP Hek, currently available to SLM Solutions, MTT and Renishaw, Realizer. Laser Cusing, however, is a proprietary name of the technologyowned by Concept Laser – a company belonging to the Hofmann Innovation Group.  At the beginning of the development of this technology, EOS and MCP Hek used also the SLM name. The MCP claimed the rights to this name first which resulted in the fact that EOS had to create its own name – DMLS. All these names refer to the technology of selective sintering and powdered metals remelting with the help of a laser, applied in layers until a durable part is obtained.

Rapid Prototyping – 3D printing; Selective Laser Melting [SLM /DMLS / LaserCusing] – laser sintering

SLA technology (Stereolithography) consists in deflecting the laser beam using the mirror system. The laser beam scans the surface of the liquid resin in the place where it should be hardened (the aim is to create a model). Commonly known as stereolithography – a light-curing resin.


Hybrid DMLS / CNC dental technology

Hybrid manufacturing dental technology is a combination of CNC milling and DMLS selective sintering methods. This method has been tested in the DentalLab laboratory in Gdańsk in Poland since 2017. This was implemented in our production in September 2018. It is used in the production of dental prostetics components used in implantology.

We use the following machines, materials and software in our laboratory DentalLab:

– 3D printer DMLS EOS M100,

– iMES iCore 750i milling machine

– annealing furnace under the protective gas atmosphere NABETHERM.

– metal powder EOS CobaltChrome SP2 (REF: 9011-0018) – medical product according to class II and MDD 93/42 / EEC directive, Annex IX, rule 8 – cobalt-based metal-ceramic alloy used for the production of dental prosthetics (Free from Ni, Be and Cd according to ISO22674)

– CAD software – 3Shape, ZirkonZahn, EXOCAD

– CAM software – MAGICS from MATERIALISE, CAMbridge from 3Shape and other

– scanners laboratory – 3Shape, MEDIT, ZirkonZahn

The DMLS manufacturing technology used is certified by EOS. Our laboratory, as the only one in Poland and one of a dozen in Europe, is on the international list of Dental Service Providers Authorized by EOS https://cdn0.scrvt.com/eos/67b76aaa8f0624f5/05192b64a9c6/EOS_Dental_Dienstleister_International_EN.pdf

The hybrid method DMLS/CNC of dental production consists of three processes:

1. development of a prepared CAD project in CAM software integrated for the SLS (Selective Laser Sintering) method and CNC milling (eg. Make & mill)

2. production of elements using DMLS sintered laser technology

3. improving of implants elements using of CNC milling technology

The use of hybrid DMLS/CNC technology allows to produce high quality implantology semi-finished products using the biggest advantages of both technologies:
- additive 3D DMLS printing – high productivity, low material waste, consistent quality of work, low manufacturing costs, required surface, improving adhesion of coovering materials applied in further production processes (veneering or cementation)
- CNC milling - high precision 

This hybrid technology DMLS / CNC has definitely fewer limitations in relation to the traditional CNC milling method of dental prosthetic elements used for implatology. Only CNC milled points must be dezigned in accordance with the CNC art and prepared as for milling (production angles, tool length, mesh structure settings for implant insertion etc.). The remaining areas are constructed without any limitations in the DMLS additive method. 

An additional advantage of the method is low production cost, which translates into low prices of semifinished products for dental implants. Dental elements with points for dental implants  can already cost approx. 140€/pc.

Price examples:

Bar with 2 points for implants – approx. 140€

Bar with 3 points for implants – approx. 200€

Bar with 4 points for implants – approx. 270€

Estimated prices of semi-finished dental implant products in technology DMLS/CNC in DentalLab

Examples of dental applications

 

Additive 3D printing method based on DMLS / SLM / Laser Cusing laser metal sintering has opened a new chapter in the development of modern technologies for the production of dental prosthetics components. Companies manufacturing DMLS / SLM / Laser Cusing pronting machines, manufacturers of CNC milling machines and users of these have started to improve their manufacturing methods and one of them is to combine DMLS / SLM / Laser Cusing sintering technology with precise milling. The earliest example is the SINT & MILL method patented by SISMA.

Laser metal sintering

** DMLS technology, i.e. Direct Metal Laser Sintering is a 3D metal printing technology which has been developed for over 20 years by EOS. The idea of prototyping metal parts using the DMLS method has evolved into mature production technology, offering unique design freedom for designers from various industries.

The repeatability of strength parameters of the created parts as well as the number of industrial and medical production implementations are elements that distinguish the DMLS method from similar SLM or LaserCusing solutions. The idea behind this technology is to produce complex shapes that can not be produced with foundry methods from hard-to-machine materials.

Advantages of DMLS/SLM/Laser Cusing technology in dental prostherics:

  • acceleration of production processes
  • increasing the accuracy and quality of performance
  • producing crowns and dental bridges from biocompatible certified alloys
  • the ability to create custom elements
  • high density of the manufactured element (100%)
  • reduction of material stress through appropriate production technology, quaranteed by the printer manufacturer EOS

The operation of DMLS / SLM / Laser cusing machines

Machines operating in the DMLS / SLM / Laser Cusing technology apply the layers of carefully composed metal powder to the work platform.

Then, on each layer, this powder is remelted in the element of the object being created with a very precise laser beam and adequate power. Such a printing takes place in a protective atmosphere of an inert gas, e.g. argon or nitrogen. The key aspect of the 3D printing process is the need of very precise control of the laser beam and continuous cleaning of the shielding gas from impurities arising during remelting. These are often impurities with a porous surface and may contain residual amounts of metal oxides and trapped gas bubbles. If the contamination falls on the melted surface and then is covered with another layer of powder, it can be embedded in the material structure, causing precipitation of a different density than the alloying material. The production quality results, therefore, from the experience of the printer manufacturer, the quality of metal powder and the accuracy and cleanliness of service.

The general functioning principle of DMLS, SLM (Selective Laser Melting) and LC (Laser Cusing) technologies is similar. The variety of technology naming results from the registration of names as trademarks. Each SLM or LC machine manufacturer takes into account limitations to patent rights and pays a patent fee to EOS (as the original creator of this method) while using several own solutions that distinguish one technology option from another. An example is the use of a rubber spreading powder in SLM machines instead of a steel or ceramic blade used in DMLS technology.

What distinguishes EOS DMLS machines

EOS is a company that sets the direction for the development of laser remelting technology for metal powders and plastics. It takes into account the quality and the number of installed systems, industrial implementations and organizational structure. Since 1994 DMLS technology is transforming from rapid prototyping technology to production technology for very demanding elements. Due to the long-term cooperation of the EOS brand with its key clients from many industries, DMLS technology is the most commonly implemented solution for the production of metal components using 3D printing.

The M280 and M290 machines produce components for GE’s and UTC’s aircraft engines. In addition, other aviation companies such as MTU and RolsRoyce are preparing for new implementations with the use of DMLS technology. The EOS machines have been used for many years instead of milling and casting, in order to produce dental components. These machines are also used in production of implants for individual patients.

3D Printing Dental technology SLM / DMLS / LaserCusing – laser sinters / sinters of metal and SLA – light-cured resin models / technology*

* DMLS (Direct Metal Laser Sintering) is a name registered byf the German company EOS (Electro Optical Systems). SLM (Selective Laser Melting) is a registered company name of MCP Hek, currently available to SLM Solutions, MTT and Renishaw, Realizer. Laser Cusing, however, is a proprietary name of the technologyowned by Concept Laser – a company belonging to the Hofmann Innovation Group.  At the beginning of the development of this technology, EOS and MCP Hek used also the SLM name. The MCP claimed the rights to this name first which resulted in the fact that EOS had to create its own name – DMLS. All these names refer to the technology of selective sintering and powdered metals remelting with the help of a laser, applied in layers until a durable part is obtained.

Rapid Prototyping – 3D printing; Selective Laser Melting [SLM /DMLS / LaserCusing] – laser sintering

SLA technology (Stereolithography) consists in deflecting the laser beam using the mirror system. The laser beam scans the surface of the liquid resin in the place where it should be hardened (the aim is to create a model). Commonly known as stereolithography – a light-curing resin.

Guidelines for CAD / CAM cooperation – scanning / printing / 3D milling in Dental technologies

[EOS, IMES, ZirkonZahn, MEDIT, EXOCAD, 3Shape, DentalWings – 3D printing Dental in SLM / DMLS / LaserCusing technology – laser sinters / metal sinters and SLA – models / technology of light cured resin *]

The laboratory has implemented an electronic service system that enables secure communication in a closed system, protected by securities similar to the banking systems security. Therefore, the cooperation can be carried out instantly and safely. In addition, the cooperators can use their user panels what gives them an access to the CRM business functions, ERP such as event archiving, file and model archiving, notifications, settlements, reporting, dispatches, complaints and more.

You do not have to fill in forms anymore, just go to the laboratory website or to your panel and send files reay for production. The rest will be done by the B2B dental24 IT system, saving everything and automatically sending notifications to the right people. All this takes place in the SaaS dental24 system, protected by the highest-class security, certificates and encryption keys that exceed the security level of some banking systems.

If you have any questions, doubts or need further information, we enable immediate contact with the CAD / CAM department, providing telephone lines and electronic channels of communication, including Skype. An experienced team is able to answer all your questions at any time.

Preparing files for DSLM / SLM printing

Below you can find the guidelines proposed by EOS and suggestions from our technicians marked with an asterisk (*), necessary for proper preparation of files for 3D printing in DSLM / SLM technology, and for sintering:

 

  • Some CAD software is intended for milling processes. Designed files may have holes in the grid, consist of several grids and be leaky, so they can not be used in the DMLS / SLM printing process.

  • File intended for 3D printing must have one grid – closed and tight.

  • A single STL file can not consist of several separate objects.

  • The densely triangulated grid guarantees the best surface. In the case of too thin triangulation, the surface of the object may not be sufficiently detailed.

  • The crown adjustment depends on the triangulation of the inner surface of the crown. For the best surface quality of the model:

– use a spray to scan on reflective surfaces

– set the high-quality scanning.

 

* According to our technicians experience, in order to reduce the number of errors in the grid, we suggest checking the settings of the angle parameters and the space at the neck of the crown (given below). It is a detailed element and has a complicated grid, in which there may be many intersecting surfaces.

 

ustawienia parametrów skanera

 

Bridges and crowns – wall thickness

The recommended wall thickness in the design is 0.5mm. The minimum wall thickness should be 0.4 mm. In the case of a smaller value, there is a risk of damage to the element in the printing process and during further manual processing.

projektowanie_koron_i_mostow_pod_DMLS_SLM_1

 

Bridges and crowns – cement space

Cement space and additional space values are suggested values. Usually, the amount of space depends on the shape of the crown and the preferences of the dentist.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_2

Bridges and crowns – narrowings

The narrowings should not be too large. If the value is too low, there is a risk that the walls surfaces will be too thin for a stable printing process. The values provided are EOS recommendations and also depend on the software used.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_3

Bridges and crowns – finishing lines of the preparation

The values given are the values suggested by EOS. The size of the preparation depends on the CAD software and the preferences of the dental technician.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_4

 

Bridges and crowns – elements connecting points in the bridge pontic

The thickness of joints depends on the shape, number of points and surface.

 

EOS recommends a minimum sectional area thickness of 6mm²  for the pontics in the area of the anterior teeth and 9mm² for the area of premolars and molars.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_12

 

Bridges and crowns – the ceramics thickness

Foundation design

Ceramics should have a thickness of 0.8 to 2.0 mm. If the ceramic is thicker than 2mm, cracks may occur due to internal stresses in the material.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_5

 

The foundation design must be properly selected to the ceramic shape in order to avoid the ceramic thickness above 2mm.

 

projektowanie_koron_i_mostow_pod_DMLS_SLM_6

 

The shape, thickness and position of the bridge pontic joints must also be properly selected.

The point must be adequately supported from the base by the foundation.

 

Surface preparation – porcelain firing

 

* Cut off of supports

Sintered prosthetic products must be supported by longitudinal structures (supports) during laser smelting in order to:

– supporting the element during production

– prevent deformation of melted metal

– dissipate heat

Each product in the unfinished state is cut off from the platform together with support structures, which must be removed so that the product could undergo the next processing steps. Support structures should be removed with profiled pliers or combination pliers. In order to remove supports, grasp them with pliers, twist gently and break.

 

 narzędzia

 

Supports have different exposure parameters than other prosthetic elements, so wringing / breaking them is much easier. Do not break the supports by grabbing the element, because it may cause plastic deformation or product destruction. In case of difficulties, it is recommended to capture and unscrew supports one at a time.

 

  spiek

 

Surface preparation

The surface of the prosthetic product can be finished with a drill, a diamond-coated milling cutter or a carbide. After finishing, the surface should be sandblasted with Korox (AlO) at a pressure of 3-4bar and cleaned with a steam jet (steamer).

 

Firing ceramics

Opaquer should be applied in two phases. The first, thin layer (Washbrand) and the second layer of opaquer. Wash under running water before applying the next layer of ceramics. EOS recommends a long cooling phase (up to approx. 600 ° C). Remove ceramics only mechanically. Hydrofluoric acid causes metal corrosion.

 

Ceramics

Use ceramics that comply with ISO 9693 with firing temperatures up to 980 ° C. Ceramics with reduced firing temperature can also be used.

 

Ceramics that comply with ISO 9693

 

Veneering material (introduction)

Manufacturer CTE (25-500°C [E-6/K] CTE (25-500°C) of suitable alloys[E-6/K] Firing Temperature Range [°C]

Uwagi

VM 13 Vita 13,1-13,6 13,8-15,2 880-890
Omega 900* Vita
Duceram KISS Degudent/ Dentsply 13,0 (25-600°C) 13,8-15,4 890-930
HeraCeram Heraeus Kulzer GmbH 12,7 13,5-14,9 850-880, bonder for non-precious: 980
Vintage Shofu Opaquer: 12,2Dentine: 13,4 13,6-15,0 915-960
Vintage Halo Shofu Opaquer: 13,0Dentine: 12,6 13,4- 14,7 900-950
IPS d.Sign Ivoclar 12,0-12,6 13,5-14,9 830-900
Initial MC GC 13,1/13,3 13,8-14,9 890-980
EX3 Noritake 12,4 13,4-14,5 930-960
Reflex Wieland 13,1 13,8-15,1 880-930
Creation Geller 13,4 13,8-14,9 900-980
Synsspar Jeneric Pentron 13,1 ?? 920-970

**informations from www.bibusmenos.pl

 


Communication systems

The company enables cooperation in all the most common CAD / CAM technologies.

It has its communication / cooperation system and is also connected to closed systems dedicated to selected products. Thanks to the latest and comprehensive equipment, we can perform the most complex orders in the shortest possible time and with the highest quality, confirmed by appropriate certificates.

3Shape Communicate™

The communication system between users of 3Shape products

dental24.cooperation

Co-operation system in the dental prosthetics industry enabling safe and instant transfer of digital files in various technologies. The open system transfers files of any type, e.g. STL. This system also gives many additional opportunities to make cooperation more attractive.