3D printing in dentistry is now central to many workflows — from models, surgical guides, and dentures, to temporary and permanent crowns, aligners, and more. But it wasn’t always this way. The evolution of 3D printing in dentistry reflects advances in materials, software, regulatory approvals, speed, and accessibility.
Below is a timeline of how 3D printing gradually became what it is today in dental practice.
1980s – The concept of “rapid prototyping” (what eventually evolved into 3D printing or additive manufacturing) was developed. Researchers began exploring ways to build physical objects layer by layer from digital designs.
1986–1987 – Charles Hull patented stereolithography (SLA), which used UV-curable resin cured layer by layer using a laser. That was foundational for future dental resin-based printing.
Late 1990s – Dentistry begins to experiment: early applications of 3D printing (or rapid prototyping) in dental labs for model work, prototypes, surgical guides, and implant planning. Machines were large, expensive, materials were limited.
CAD/CAM becomes mainstream — Even before “modern” resin- and light-based 3D printing caught on, dental CAD/CAM (computer-aided design and manufacture) was in use. Milling machines, digital impressions, and software enabled a partially digital workflow.
Early resin-based systems – Early SLA printers in labs were used to create highly detailed models, wax-ups, and prototypes. Materials and resolution were improving slowly. However, cost, speed, and material constraints prevented wide adoption in general dental practices
With better resins, higher-resolution SLA / DLP printing, and more reliable hardware and software, applications expanded beyond models to include surgical guides, temporary prosthetics, dentures, orthodontic appliances, and other indirect restorations.
Software interoperability improved: STL file standards, integration between intraoral and lab scanners, digital design workflows. Labs and dental schools begin training on digital dentistry, including additive manufacturing.
In this period, DLP-based printers in dentistry became more common, enabling faster layer curing, better resolution, lower cost, and better materials chemistry.
Print materials diversified: more biocompatible resins, high translucency materials for crowns and veneers, improved temporary crown materials, better orthodontic materials.
Dental practices began installing chairside 3D printers, not just labs. This facilitated faster delivery times (same-day or within days) for models, guides, temporaries.
Since 2021, the technology on 3D printing for dentists has erupted - finding new and innovative ways to improve and speed up the process or print in ways never before thought possible.
4D printing / dynamic materials — Research into materials that respond to changes, or workflows that incorporate movement, flexible attachments, or smart resins.
Direct-print permanent restoratives — More manufacturers are pushing toward FDA/CE‑approved permanent crown, bridge, and full‑arch materials that can be printed (rather than milled or cast).
Printed aligners / direct-print appliances — While thermoform plus trimming was standard, the emergence of direct‑print aligners (and related trimming tools) is creating new workflow efficiencies.
Improved regulatory, safety, and post‑processing standards — More attention to biocompatibility, curing protocols (e.g., using glycerin to eliminate oxygen inhibition layer), verification of fit, strength, long‑term durability.
Software and workflow integration — Better integration between scanning, CAD/CAM, slicing software, print machine, post‑processing, and delivery. Also integration for patient records, insurance documentation, and quality assurance.
These innovations didn’t happen in a vacuum. Several major forces pushed 3D printing in dentistry forward:
Demand for speed and convenience — Patients and clinicians alike value reduced turnaround time, fewer visits, same‑day solutions.
Improvement in materials science — Better resins, better ceramic fillers, stronger print materials, improved optical properties.
Lower costs of hardware and software — As consumer‑grade and dental‑grade 3D printers became more affordable and reliable.
Regulatory approvals — More materials cleared for intraoral, permanent use. Approvals for devices, adhesives, etc.
Digital scanning, CBCT, photogrammetry — Better data capture leads to better print outcomes. Accurate scans are essential for precision.
Even with rapid progress, there have been and still are challenges:
Maintaining mechanical strength and durability in printed permanent restorations.
Ensuring fit precision — marginal adaptation, antagonistic occlusion, long-term wear.
Biocompatibility, residual unpolymerized resin, curing protocols.
Post‑processing burdens — cleaning, curing, removing supports, verifying quality.
Regulatory and insurance landscapes still catching up. Costs of materials and maintenance.
Training and skills – software, design, printing, finishing, bonding.
Where is 3D printing in dentistry headed next?
Fully printed permanent crowns and bridges with high strength, esthetics, durability.
Direct‑print aligners, sleep appliances, obturators and more specialized devices.
Integration of artificial intelligence in design, predictive fit, and automated support generation.
Smart materials: resins that respond to changes, e.g. color‑changing, self‑reporting, or having antimicrobial properties.
More compact, faster printers for in‑office “chairside” use.
Improved digital workflows including CBCT, photogrammetry, IOS, CAD, 3D printing, finishing, and chairside cementation all optimized together.
The history of 3D printing in dentistry is a story of gradual evolution — from large, experimental machines making models to today’s chairside, high‑precision, biocompatible workflows. Technology, materials, software, and regulatory frameworks have all matured, enabling transformative gains in speed, patient experience, and personalization.
For dental professionals, staying abreast of this history isn't just academic—it helps in understanding why certain workflows succeed, what pitfalls to avoid, and how to remain nimble in adopting future advances.
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