Stratasys PolyJet Multi-Material 3D Printing with Automated Washing Workflow Scales Dental Production Efficiency
The dental manufacturing industry has undergone a remarkable transformation in recent years, with 3D printing technology at the forefront of this revolution. Olivier Mangot, Co-Director of Ident'M laboratory and its cutting-edge production center Ninety!, has leveraged this technology to dramatically scale operations. After investing in three Stratasys J5 DentaJet printers, their facility now produces up to 500 high-precision models, aligner arches, and gingival masks daily. This production volume required an optimized workflow for support removal, which they achieved through integration with PostProcess Technology's DEMI X 520 automated washing machine.
Ninety!, a state-of-the-art dental production facility located in Saint-Etienne, France, has enabled Ident'M and laboratories throughout France to achieve new levels of precision and efficiency for dental applications.
"Stratasys PolyJet technology has revolutionized our manufacturing capabilities," explains Olivier Mangot, Co-Director of both divisions. "The J5 DentaJet gives us the ability to 3D print parts with complex geometries and multiple materials—both rigid and flexible—in a single printing session. This capability is absolutely transformative for dental applications."
The investment in three Stratasys J5 DentaJet 3D printers has enabled Ninety! to produce several hundred parts daily with consistently accurate results. The DentaJet's unique capabilities allow for the efficient creation of highly detailed dental models and surgical guides at scale – something that would be impossible with traditional manufacturing methods.
As Ninety! scaled from 20 models to 50 models per day, and ultimately to 500 models daily, the Stratasys J5 DentaJet printers proved essential. These systems can produce multiple patient-specific models simultaneously, with each model containing precisely rendered anatomical details essential for accurate dental work.
"The DentaJet's ability to print multiple materials with different mechanical properties has been game-changing for our orthodontic and implantology applications," notes Mangot. "We can create rigid bases with flexible gingival masks in a single print, which ensures perfect alignment and significantly reduces production time."
The multi-material capabilities of the J5 DentaJet allow Ninety! to produce:
"Stratasys' PolyJet technology delivers a level of accuracy that's critical in dental applications where precision is measured in microns," explains Mangot. "The consistency across all three of our J5 DentaJet machines means we can reliably produce identical models regardless of which printer handles the job."
While the Stratasys J5 DentaJet printers enabled unprecedented production capacity, Ninety! needed to optimize the entire workflow to maintain their commitment to 24-48 hour customer delivery times. The post-printing steps for DentaJet are minimal as parts come off the printer fully cured. The only additional step involves washing off the support material with water.
"When we increased our Stratasys DentaJet production capacity, we needed to ensure that support removal wouldn't become a bottleneck," says Mangot. "The DentaJet printers were producing flawless models with a high level of efficiency, and we needed to continue that efficiency throughout the entire workflow, including cleaning."
To maximize the value of their Stratasys investment, Ninety! implemented PostProcess Technologies' DEMI X 520 machine, which was specifically adapted for PolyJet printing technology.
"PostProcess worked with us to develop a solution that preserves the exceptional quality produced by our Stratasys J5 DentaJet printers," explains Mangot. "This integration allows us to fully leverage the production capacity of our three DentaJet systems without compromising on quality."
The integrated workflow allows the Ninety! operator to remove up to 200 parts from the DentaJet printers each morning, load them into the PostProcess machine, and launch a pre-programmed washing cycle. After approximately 2 hours, the parts emerge perfectly cleaned, ready for delivery.
"The DEMI X 520 ensures we can fully realize the quality and efficiency benefits of our Stratasys printers," adds Mangot." Cleaning quality at scale is critical because the Stratasys J5 DentaJet produces geometrically complex parts with intricate details.
A significant advantage of the Stratasys DentaJet technology is its compatibility with water-based cleaning processes, eliminating the need for isopropyl alcohol (IPA) or other solvents common in dental 3D printing.
"One of the major benefits of Stratasys DentaJet technology is offering a solution without IPA-type solvents in post-processing," points out Alain Marion from PostProcess. "This creates a safer workplace environment and reduces regulatory complexity."
"Workplace health and safety is crucial in our operation," emphasizes Mangot. "Stratasys' water-soluble support material offers significant advantages over competing technologies that require flammable solvents. Combined with our automated cleaning solution, we've created an efficient, safe, and environmentally responsible production system."
“When I calculate my ROI at the end of the year, I have increased my productivity and saved money. And, I reduced my ecological impact while improving my employees’ working conditions!” explains Mangot.
The combination of Stratasys J5 DentaJet printers and complementary automated washing has transformed Ninety!'s production capabilities.
Key benefits include:
"Stratasys technology has been fundamental to our success," concludes Mangot. "The J5 DentaJet printers deliver exceptional quality and consistency at scale, and integrating complementary automated washing ensures we can maintain our commitment to fast turnaround times. Today we have a complete solution that makes us more competitive than our rivals."
