Dentsply Sirona announces partnership with Carbon for 3D printed dentures

Dentsply Sirona CarbonDentsply Sirona (NSDQ:XRAY) and 3D printing company Carbon have forged a partnership in which Dentsply will provide denture materials for use on Carbon systems.

The Dentsply Sirona denture materials for Carbon digital manufacturing solutions will be available later this year in the U.S., the companies said today.

Carbon’s 3D printers are based on its proprietary 3D printers based on its proprietary Digital Light Synthesis technology — which uses stereolithography, using light to convert a photocurable resin into a solid. Carbon’s original intellectual property involves a special window at the bottom of the resin reservoir. The window is transparent to UV light, but it’s also permeable to oxygen. Carbon’s technology drives oxygen intentionally into the very lowest part of the resin pool, saturating the first 30 to 40 microns with oxygen and creating a “dead zone” where polymerization doesn’t take place.

The result, according to officials at Carbon, is fast printing with little or no mechanical impact on the growing part.

The new partnership with Dentsply Dirona will enable a “complete digital denture solution that is superior in terms of strength and aesthetics,” said Brian Ganey, general manager of Carbon’s dental business.

“With Carbon as the leading digital manufacturer in digital dentistry and Dentsply Sirona’s global leadership in removable appliances, we can deliver an unmatched offering that benefits both the dental laboratory and the patient,” Ganey said in a news release.

Carbon has been making inroads in the medical device business in recent years, collaborating with companies including Johnson & Johnson and BD.


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How have medtech launches and prototyping evolved with 3D printing?


Here are three basic ways that 3D printing can help you get your medical device project off the ground.

Jim Medsker, Keystone Solutions Group

Formlabs 3D printing

Complete 3-D printing Form 2 package by Formlabs [Image courtesy of Formlabs]

Additive manufacturing, commonly referred to as 3D printing, began to surface in the 1980s. Since then, the technology has quickly become a valuable tool for creating plastic prototype parts in a rapid fashion. Like many emerging technologies, however, the early days of 3D printing had drawbacks.

The equipment and materials were prohibitively expensive for most companies, thus creating the initial demand for 3D printing service firms. Many of the first printers on the market came with a price tag close to $300,000. Further, the parts created were primarily for visual purposes only and typically did not have the surface finish, strength or other properties necessary to make them a fully functional part.

Roll the clock forward to the present day and the technology is not only capable of creating fully functional parts in many applications, it’s also accessible for small companies and hobbyists. Today there are several 3D printer options in the sub-$1,000 range, and many in the $3,000–$10,000 range, that produce high-quality, structurally capable parts.

(Network with Keystone Solutions Group experts at DeviceTalks West, Dec. 11–12 in Orange County, Calif.)

In the early days of the technology, materials were limited to specialized plastics with limited mechanical and thermal properties. Today materials, processes and resulting parts are wide-ranging, including:

  • Many plastic resins;
  • Elastic and dual durometer components;
  • Metals;
  • Fabrics;
  • Biocompatible scaffold materials to promote tissue growth;
  • Synthetic food products.

This advance led to the capability to produce everything from organ tissue to full-size vehicles and just about anything one can imagine in between.

For medical device startups, this means additive manufacturing is now a key asset for not only creating parts, but also in launching companies. 

Go to our sister site Medical Design & Outsourcing for a few brief examples of how 3D printing can help you get your medical device project off the ground.

Researchers created a menstrual cycle on a chip, paving the way for innovative cancer research

Researchers from Northwestern produced EVATAR, a modular system designed to replicate hormone signaling in the human menstrual cycle. Photo: Northwestern University Feinberg School of Medicine

Researchers have been looking for better ways to study human biology. Cells in a dish don’t capture the body’s complexity and generally don’t live that long. Recent advances in 3D organoids often fall short on their own. But now, researchers at Northwestern University Feinberg School of Medicine have developed a modular system that incorporates all the necessary organ types to replicate hormone signaling in the human menstrual cycle.

Called EVATAR (a combo of avatar and Eve), the system’s various modules contribute 3D models of human fallopian tube, uterus, cervix, liver and mouse ovary tissue. Microfluidics transfer a universal medium that acts like blood and carries hormonal and other signals between tissues. This communal approach produces a better model.

“They were sharing all this media and releasing factors that were propagating each other,” said Julie Kim, research professor and co-author on the team’s Nature Communications paper in a phone interview. “They survived better and responded to hormones better – more so than if they were alone in a static environment. These different cultures together in this microfluidic platform are able to survive for a whole menstrual cycle, 28 days, which is a long time for cells to grow in culture.”


The effort pulled in experts on each tissue type – Kim’s lab focused on the uterus. Draper laboratory helped engineer the various connected boxes. Because we don’t take out healthy human ovaries, researchers used mouse ovaries, but even that was a win.

“The mouse estrus cycle is only four days long,” said Kim. “But by putting it in a dish and stimulating with hormones, like FSH and LH, we got 14 days of estrogen and 14 days of progesterone.”

The research led to a lot of firsts, such as new 3D models for uterus and cervix, but it’s the applications that are generating the team’s excitement. EVATAR could enhance their ability to study many conditions, such as fibroids, endometriosis and endometrial cancer.

“If we could study tumors long-term in a microfluidic system, then we could see how tumors respond to progestin and see if we can use these types of platforms as mini clinical trials for compounds that can affect these diseases,” said Kim.

The project was spawned by NIH efforts to create a “body-on-a-chip.” The agency solicited proposals for a variety of tissues – cardiovascular, kidney, bowel – though, according to Kim, reproductive tissue was notably absent. The Northwestern team took that as a source of motivation.

Teresa Woodruff (director of the Women’s Health Research Institute and senior author on the paper) said we need a reproductive tract,” said Kim.

Their work is part of a major push to find better models to study human biology, test drugs for safety and efficacy and ultimately personalize care. Companies like Hµrel, Ascendence Bio and Tissuse have developed organs on chips. Others, like Organovo and BioBots, are creating or enabling 3D tissue printing.

Still, there’s lots more to do. The Northwestern group will be working on a male counterpart to EVATAR and there are other tissues that could improve their female model.

“We have only a couple of cell types in the endometrium,” says Kim. “There are more types that play an important role. If we put in blood vessels, immune cells and other cell types, we could see the tissue differentiate and eventually bleed.”

Can a 3D printing network for VA hospitals realize ambitions for customized prosthetics?

Photo: Stratasys’ 3D technology

Stratasys has established a 3D printing lab network as part of an agreement with Center for Innovation at the Department of Veterans Affairs. The move signals the medtech company’s ambitions to move customized prosthetics into the mainstream of healthcare.

The agreement with the Center for Innovation at the Department of Veterans Affairs will make five hospitals part of the initial network in Puget Sound, San Antonio, Albuquerque, Orlando, and Boston. They’ll be equipped with 3D printers, materials, and training to support development of custom orthotics, prostheses, and anatomical models for personalized healthcare, a company release said. The equipment is fully integrated across hospitals, generating a network for building skills and knowledge-sharing across sites. The goal is to generate better patient outcomes, but also to improve surgical collaboration, and reduce costs.

Dr. Beth Ripley, a radiologist who is leading the VA initiative, said the network marked a milestone in how the VA develops patient treatments.


“The technology not only enables 3D models of a patient’s unique anatomy for diagnosis and treatment, but can also be used to engineer personalized health solutions for veterans — including prostheses and assistive technologies,” Ripley said.

One reason why this network is so interesting is that it offers a way to improve upon the training required to make 3D printing a more integral part of hospitals. To that end, hospitals in the network will also share best practice guidance with each other. In addition to prosthetics, 3D printing can help hospitals develop organ models to prepare for complex procedures.

Last year, MedCity News noted analysts have predicted that 3D printing will be a major disruptive force in the healthcare industry before the end of the decade. According to a Gartner study published late last year, 10 percent of people in the developed world will be living with 3D-printed items on or in their bodies by 2019, and 3D printing will be a central tool in roughly one-third of surgical procedures involving prosthetic and implanted devices.

IndustryArc, the global market for 3D printing in healthcare, has projected that the market to be worth $1.2 billion by 2020.