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- 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
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
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
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
Compatible Machines & Materials
UltraCraft A2D
Learn MoreUltraCraft A2D 4K
Learn MoreModel HP UV 2.0
Learn More