The Future of Dentures: When to Print and When to Lab It

How can 3D printing transform your approach to complete denture fabrication while maintaining profitability and patient satisfaction?Dr. Russell Schafer brings a unique perspective to removable prosthodontics as a general dentist and owner of NOLA Dental-Prosthetics and General Dentistry in New Orleans, Louisiana. With a mechanical engineering background from Rice University (BS 2007, MS 2008) and LSU Dental School graduation in 2013, Dr. Schafer combines technical expertise with practical clinical experience. Despite initially despising dentures in dental school, he has transformed his practice to focus 35% on removable prosthodontics, earning recognition as "the denture guy" in his community. He specializes in digital design and printing, with proficiency in Blue Sky Bio, Meshmixer, and Exocad software, and has extensive experience with multiple 3D printers including SprintRay Moonray, Ackuretta Sol, and Phrozen Mini 8K systems.This episode explores the practical integration of 3D printing technology into complete denture workflows, examining when printed prosthetics excel versus when conventional laboratory processing remains the gold standard. Dr. Schafer shares his hybrid approach that serves both fee-for-service and Medicaid populations, offering patients customized treatment options based on aesthetic demands, financial constraints, and clinical requirements. The discussion covers material considerations, workflow efficiencies, and the clinical decision-making process that determines treatment pathways.Episode Highlights:Immediate dentures represent the optimal starting point for dentists entering 3D printing, offering high profit margins and allowing for easy remakes if adjustments are needed. The workflow involves scanning patients before extraction, digitally removing teeth, designing the prosthetic, and delivering the printed denture immediately following extractions.Material simplification maximizes efficiency and profitability by stocking only two resin shades (010 bleach shade and A1) and using one to two tooth molds for all printed dentures. This approach prevents waste from expired materials while maintaining clinical versatility across most patient presentations.A "buy one, get one free" protocol allows dentists to compare their printed work against experienced laboratory technicians, providing valuable learning opportunities while delivering additional patient value. Patients receive both a printed denture and a conventional laboratory-processed prosthetic for comprehensive treatment outcomes.Current printed denture materials demonstrate approximately 5% fracture rates, typically occurring along the palatal midline in challenging cases with minimal vertical dimension and opposing natural dentition from premolar to premolar. These limitations guide case selection protocols for optimal clinical outcomes.Aesthetic demands primarily determine treatment selection, with high-aesthetic cases referred to laboratory processing while functional-focused patients receive printed prosthetics. This approach aligns material capabilities with patient expectations and maintains practice efficiency across diverse demographic populations.Perfect for: General dentists interested in expanding removable prosthodontic services, practitioners considering 3D printing integration, and dental professionals serving diverse socioeconomic patient populations seeking efficient denture workflows.Discover how strategic technology adoption can differentiate your practice while delivering quality prosthodontic care across all patient demographics.