No Separator. No Stone Duplication. 2 Days Saved.

How Model ES 2.0 transformed GPS Digital Dental Lab‘s self-cure RPD workflow - from inconsistent separator results to clean release.

 

The Lab

 

GPS Digital Dental Lab ("GPS"), founded in 2002 in Orlando, Florida, is a full-service dental laboratory that has undergone a complete digital transformation over the past 15 years. Now led by CEO Andrew Perricone, the lab has fully embraced 3D printing across every aspect of production – from crowns and bridges to implants, digital dentures, and digital partials.

 

Today, literally every single case that comes through the lab involves a 3D printer in some aspect. With 18 HeyGears 3D printers across two facilities, GPS has become one of the most digitally integrated labs in the U.S.

 

 

The Challenge

 

Processing acrylic on printed models often comes with a built-in challenge: the chemistry between the resin and the acrylic can cause adhesion.

 

The HP grey model resin they were using from HeyGears was accurate and reliable. But in self-cure RPD applications, acrylic would stick to the surface of printed models. This isn't a flaw of the material; it's simply the nature of the chemistry between printed model resins and self-curing acrylics.

 

The workaround: apply separator. And even then, results were inconsistent.

"We used to put so much separator on these models. Sometimes it would work and sometimes it wouldn't. It was hit or miss."

 

The standard practice: duplicate every printed model in stone.

 

When separators failed, or when the lab needed guaranteed results, they would duplicate the printed model in stone – a time-consuming process that added friction to their workflow.

 

The RPD lab didn't have a model room of its own. So whenever they needed a stone duplicate, they had to:

• Transport models from the RPD lab to the main lab's model room.
• Wait 1-2 days for duplication, depending on how busy the main lab's model room was.
• Pour, trim, and articulate stone models.
• Transport them back to the RPD lab to continue processing.

 

So the lab had two imperfect options: risk it with separator, or wait for stone duplication.

 

The Solution: HeyGears Model ES 2.0

 

Enter HeyGears Model ES 2.0 (originally introduced to GPS as Model ES 1.0 in ivory) – a non-stick dental model resin with built-in release for self-curing acrylics.

 

The results were immediate:

• No separator needed in self-cure RPD processing.
  The non-stick resin eliminates the need for separator entirely in their self-cure acrylic application workflow. No coating, no drying, no cleanup. Just print, apply acrylic, and release.
• No more stone duplication.
  Because acrylic releases cleanly from models printed with Model ES 2.0, the lab no longer needs to duplicate models in stone as a backup. The work stays in-house.
• Print two models at once.
  Instead of printing one grey model, duplicating it in stone, and waiting, GPS now simply prints two Model ES 2.0 models simultaneously.
• 2 days saved.
  Eliminating the stone duplication step removes approximately 2 full days from each case turnaround time. Cases get processed faster and back to customers sooner.
• Identical fit and specs.
  Model ES 2.0 delivers the same dimensional accuracy and fit as the Model HP grey resin previously used. No compromise. Just a better workflow.

 

Customer Feedback

 

From technicians: All in all, very positive.

 

From a non-digital lab in North Carolina: Andrew recommended Model ES 2.0 resin to a small lab that wasn't digital and was struggling with printed models. He provided them with a free sample for their first case.

 

The customer called a couple days later, thrilled.

"It works just like a stone model - except I don't have to do the whole process of duplicating it, pouring it, trimming it, waiting for all these things."

 

From Andrew Perricone, CEO:

"This resin (Model ES 2.0) for us has been a huge game changer."

"If another lab was considering using a non-stick model resin, I would tell them to go for it."

 

The Bottom Line

 

For GPS, Model ES 2.0 didn't just improve a single step – it eliminated an entire workflow bottleneck.

 

Before	After
Print grey (Model HP) model → duplicate in stone → wait 1-2 days	Print two Model ES models simultaneously
Cross-building transport	All in-house
Inconsistent separator results	Clean release
1-2 day delay	2 days saved
Fragmented workflow	Streamlined, end-to-end

 

No Separator. No Stone Duplication. 2 Days Saved.

 

For GPS, this wasn't just an incremental improvement. It was the solution to a problem they had faced for years - inconsistent results, days of waiting. What started as a trial became a fundamental change in how they process self-cure RPD cases.

 

That's the Model ES 2.0 difference. And for GPS, it made all the difference.

 

Ready to see what Model ES 2.0 can do for your lab?

 

Generate your custom feasibility report – and see exactly how much you could save.

 

👉 Generate Your Report: es.heygears.com

 

For use with HeyGears A2D / A3D printers with LRF Combo. Post-processing tailored to your acrylic brand.

 

 

For more information please contact sales@heygears.com

 

 

 

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