Challenges of the Traditional Process
  • Time-consuming
  • High maintenance cost
  • Potentially dangerous process of cutting & grinding gypsum material

Timeline

  • Gypsum model casting process

    1h
  • Drill and position the pins on the relative dies, align model with articulator

    2h 20min
  • Separate the Dies From the Model & Trim the Edges

    10min
  • Scan the Gypsum Model & Dies, design restoration products based on the scan

    15min
  • Manufacture the designed files with CAM

    20min
  • Color the crowns and sinter

    4h 20min

Gypsum model casting process

time

1h

Drill and position the pins on the relative dies, align model with articulator

time

2h 20min

Separate the Dies From the Model & Trim the Edges

time

10min

Scan the Gypsum Model & Dies, design restoration products based on the scan

time

15min

Manufacture the designed files with CAM

time

20min

Color the crowns and sinter

time

4h 20min

Total time: 8.5h

HeyGears' scanning solution without model separation

  • Gypsum model casting

    1h
  • Filter and select the models compatible for the process with the fixtures provided by HeyGears, then trim the dies

    5min
  • Scan the trimmed model and make sure edges are clear to be seen

    5min
  • Design restoration products based on the scan

    15min
  • Manufacture the designed files with CAM

    20min

    Pre-process the model with Streamflow and assign jobs to printer

    2min
  • Color the crowns and sinter

    4h 20min

    Print and post-process accordingly

    1h

Gypsum model casting

time 1h

Filter and select the models compatible for the process with the fixtures provided by HeyGears, then trim the dies

time 5min

Scan the trimmed model and make sure edges are clear to be seen

time 5min

Design restoration products based on the scan

time 15min

Manufacture the designed files with CAM

time 20min

Pre-process the model with Streamflow and assign jobs to printer

time 2min

Color the crowns and sinter

time 4h 20min

Print and post-process accordingly

time 1h
Total time: 6h

The new process saves over 30% of the time used compared to the traditional method.

Model Filtering

A 3D printer must have more than two cameras with a significant perspective disparity to capture the fine details between adjacent teeth and maximize production efficiency when scanning unseparated models.

How to Quickly Tell if You Can Scan a Full Model

Based on 3D scanning principles, HeyGears develops fixtures with different insert angles to simulate the optical pathways of the scanner. Users can quickly identify if the model is scannable or not before the scanning process begins.

Model Filtering

Fixture used for filtering

The Accuracy of the Scanned Unseparated Models Versus Gypsum Cast Models

Most dentists base their judgment of crown placement on the fitting with adjacent teeth. Labs use articulating paper of different thicknesses during QC. The optimal gap between adjacent teeth is 0.03mm. Below are the comparisons between the unseparated gypsum and a 3D printed model after a scan.

3D printed models & gypsum printed models are identical after being made in optimal printing environments.

case1 Max deviation: 0.017 mm

case2 Max deviation: 0.02

case3 Almost no deviation

Model Filtering

case1

Max deviation: 0.017 mm

Crown Fitting Results Between a Printed Unseparated Model and Gypsum Cast Model

The calibration of scanners and 3D printers and the cleaning of the optical pathways of the printers are vital to creating accurate models. Due to the gypsums nature of not being abrasion-resistant, the crown fitting on the gypsum models is looser than that of 3D printed models. As a result, the QC standard must be adjusted accordingly with a new digital production process.

  • Crown fitting on printed unseparated model
  • Crown fitting on gypsum cast model
  • CASE 1

  • CASE 2

  • CASE 3

Advantages of the scanning
without model separation

  • No need to separate the dies or align them on the articulator
  • It takes 30% less time when model printing
  • CAM & sintering processes can operate at the same time
  • Use of abrasion-resistant material
  • The digital process reduces human dependency and management cost

Advantages of the scanning
without model separation

  • No need to separate the dies or align them on the articulator
  • It takes 30% less time when model printing
  • CAM & sintering processes can operate at the same time
  • Use of abrasion-resistant material
  • The digital process reduces human dependency and management cost

Compatible Machines & Materials

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