Carbon Unveils New 3D Printing Resin for Dental Applications

Key Takeaways:

• Carbon introduces FP3D, a flexible resin for removable partial dentures.
• The material leverages dual-cure chemistry to enhance durability and flexibility.
• FP3D is under FDA review and expected to launch in late 2025.
• Carbon also releases software tools to streamline dental lab workflows.

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Introducing FP3D: A New Era for Removable Partial Dentures

Carbon, a leader in 3D printing technology, has announced the development of FP3D, a novel flexible resin tailored for removable partial denture (RPD) applications. Unveiled at Lab Day Chicago, this innovation marks a significant step forward in dental materials, as it becomes the first Carbon dental resin to harness the company’s proprietary dual-cure chemistry. This technology has already proven its worth in industries such as sports equipment, footwear, and cycling, where durability and performance are paramount.

FP3D was engineered to address the limitations of single-cure resins, which have often struggled to meet the rigorous demands of dental applications. According to Carbon, single-cure resins can fall short in terms of durability and retention, critical factors for RPDs. To overcome these challenges, Carbon embedded secondary heat-activated chemistry within FP3D, enabling the material to strengthen during a post-print bake step without compromising viscosity or accuracy during the printing process.

The company describes the outcome as “robust engineering-grade parts through isotropic mechanical responses with high durability.” This advancement positions FP3D as a viable alternative to traditionally produced polymer-based flexible partial denture materials, offering similar properties while leveraging the precision of 3D printing.

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Regulatory Hurdles and Market Availability

While FP3D shows promise, its journey to market is contingent upon regulatory approval. The material is currently undergoing review by the FDA for 510(k) clearance, a necessary step before it can be widely adopted in clinical settings. Carbon anticipates that FP3D will become commercially available in late 2025, provided it meets all regulatory requirements.

This timeline reflects the company’s commitment to ensuring safety and efficacy, aligning with industry standards for medical and dental devices. Dental professionals and labs will need to monitor updates on the FDA’s decision, as the material’s approval could reshape workflows and patient outcomes in the field of removable partial dentures.

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Enhancing Dental Lab Workflows with New Software Tools

In tandem with the introduction of FP3D, Carbon has rolled out new software tools designed to automate and streamline dental lab operations. Among these innovations is a “no-code, user-friendly” automatic print preparation capability. This feature simplifies tasks such as nesting and queuing, allowing technicians to focus on higher-value activities while reducing manual intervention.

Another notable addition is the AO Polishing Cassette Expansion, which integrates advanced light-scattering technology to enable polishing directly during the printing process. Compatible with Carbon’s M3 and M3 Max printers, this tool has been validated for use with materials like Dentsply’s Lucitone Digital Print and Desktop Health’s Flexcera Base. The result is smoother and clearer parts straight off the printer, reducing the need for additional post-processing steps.

These software advancements underscore Carbon’s holistic approach to innovation, addressing not only material science but also the broader ecosystem of dental lab workflows. By combining cutting-edge materials with intuitive software solutions, the company aims to empower dental professionals to deliver better results more efficiently.

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Implications for the Dental Industry

The launch of FP3D and accompanying software tools highlights Carbon’s ongoing efforts to bridge gaps in dental manufacturing. By addressing the shortcomings of existing materials and streamlining production processes, the company is positioning itself as a key player in the evolution of digital dentistry.

As dental labs and practitioners await the commercial availability of FP3D, its potential to enhance the performance and reliability of removable partial dentures remains a topic of interest. If successful, this development could pave the way for broader adoption of 3D printing technologies in restorative dentistry, offering patients improved comfort and functionality.

For now, the dental community will closely follow the progress of FP3D through the FDA review process, as well as the integration of Carbon’s new software tools into lab environments. These advancements may not only redefine how dental appliances are made but also set new benchmarks for quality and efficiency in the industry.