3D Printing Workflow Integration: Formlabs vs NextDent Crown Production
Photo by Caroline LM
📌 TL;DR: This guide covers D Printing Workflow Integration: How Formlabs Dental LFS vs NextDent Streamline In-Office Crown Production, including how AI-powered tools like Intake.Dental are helping practices implement these solutions today.
The shift toward in-office crown production has accelerated dramatically, with over 40% of dental practices now considering or actively implementing chairside manufacturing solutions. While CAD/CAM milling dominated the initial wave of digital dentistry, 3D printing has emerged as a compelling alternative, offering unique advantages in material versatility, complex geometry production, and cost-effectiveness for smaller batch sizes.
📑 Table of Contents
- The Digital Crown Production Landscape
- Print Management and Workflow Automation
- Material Handling and Post-Processing Integration
- Practice Management Software Integration
- Cost Analysis and ROI Considerations
- Implementation Strategy and Staff Training
- FAQ
However, the success of any 3D printing implementation hinges not just on hardware quality, but on seamless workflow integration. Practices investing in advanced printing technology often discover that the biggest challenges lie in patient data management, treatment planning coordination, and maintaining consistent quality across the entire production pipeline. Two leading platforms—Formlabs Dental LFS and NextDent—have developed distinct approaches to addressing these workflow integration challenges.
The Digital Crown Production Landscape
Modern dental 3D printing workflows typically involve five critical stages: patient data capture, treatment planning, design optimization, printing and post-processing, and quality verification. Each stage presents integration opportunities and potential bottlenecks that can significantly impact practice efficiency and patient outcomes.
Formlabs has positioned its Dental LFS (Low Force Stereolithography) platform as an ecosystem solution, emphasizing software integration and automated workflow management. Their approach centers on PreForm software and cloud-based print management, designed to minimize manual intervention and reduce operator error rates.
NextDent, acquired by 3D Systems, focuses on material science and precision manufacturing, offering a more hardware-centric approach with extensive material options and industrial-grade printing capabilities. Their workflow emphasizes customization and compatibility with existing dental software ecosystems.
Print Management and Workflow Automation
The most significant differentiator between these platforms lies in their approach to print job management and workflow automation. Formlabs Dashboard provides cloud-based fleet management, allowing practices to monitor multiple printers, track material usage, and receive predictive maintenance alerts. This centralized approach particularly benefits multi-location practices or those with high-volume production requirements.
NextDent’s workflow centers around their NextDent Ortho Clear and Crown resins, with emphasis on material consistency and predictable outcomes. Their integration strategy focuses on compatibility with leading dental CAD software including 3Shape, Dental Wings, and exocad, rather than proprietary workflow management.
For practices prioritizing comprehensive patient data management throughout the production process, solutions like Intake.Dental become crucial workflow components. Built by a practicing dentist, this platform ensures that patient consent forms, medical histories, and treatment documentation remain accessible and properly encrypted throughout the digital production workflow, addressing a common gap in 3D printing implementations.
Material Handling and Post-Processing Integration
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Post-processing represents a critical workflow bottleneck that both platforms address through different strategies. Formlabs Form Wash and Form Cure stations integrate directly with their printing ecosystem, providing automated cleaning and curing cycles with minimal operator intervention. The system tracks resin types automatically and adjusts post-processing parameters accordingly.
NextDent’s approach emphasizes material flexibility and custom post-processing protocols. Their resins are designed to work with standard dental lab equipment, allowing practices to integrate 3D printing into existing lab workflows without requiring entirely new post-processing infrastructure.
Quality control integration varies significantly between platforms. Formlabs provides built-in quality monitoring through their Dashboard system, tracking print success rates and identifying potential issues before they impact patient care. NextDent relies more heavily on operator expertise and traditional dental lab quality control methods.
Practice Management Software Integration
Seamless integration with existing practice management systems represents a make-or-break factor for successful 3D printing implementation. Both platforms offer different approaches to this challenge, with varying degrees of direct integration and third-party compatibility.
Formlabs has developed partnerships with major dental software providers, enabling direct case transfer from treatment planning software to print preparation. Their API allows custom integrations for practices with specific workflow requirements or proprietary systems.
NextDent’s strategy emphasizes open-file format compatibility, supporting STL and PLY files from virtually any dental CAD system. While this provides maximum flexibility, it may require additional workflow coordination to maintain proper case tracking and patient data association.
The patient intake and documentation aspect of 3D printing workflows often requires additional consideration. Intake.Dental addresses this need with customizable consent forms and medical history templates that integrate seamlessly with any practice management software, including Dentrix, Eaglesoft, and Open Dental. This ensures proper documentation and consent for 3D printed restorations while maintaining HIPAA-compliant cloud storage with AES-256-GCM encryption.
Cost Analysis and ROI Considerations
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Total cost of ownership extends far beyond initial hardware investment, encompassing material costs, maintenance requirements, operator training, and workflow integration expenses. Formlabs typically requires higher upfront investment but offers more predictable ongoing costs through their integrated ecosystem approach.
NextDent systems often present lower entry costs but may require additional investment in compatible post-processing equipment and workflow integration tools. Material costs vary based on specific resin requirements and volume purchasing agreements.
Practices should factor integration costs into their ROI calculations, including potential practice management software upgrades, staff training requirements, and workflow optimization consulting. The complexity of patient data management during digital production workflows may require additional solutions to ensure compliance and quality documentation.
Implementation Strategy and Staff Training
Successful 3D printing workflow integration requires comprehensive staff training and gradual implementation strategies. Formlabs provides structured training programs through their Dental Advisory Board and online certification courses, emphasizing their integrated workflow approach.
NextDent offers more flexible training options, often delivered through their network of authorized dealers and dental lab partners. This approach can provide more customized training based on specific practice needs and existing workflows.
Both platforms benefit from phased implementation strategies, beginning with simple cases and gradually expanding to more complex restorations as staff expertise develops. Practices should also consider how patient communication and consent processes will adapt to in-office 3D printing capabilities, potentially requiring updates to intake forms and treatment explanation protocols.
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FAQ
How long does the typical 3D printed crown workflow take from scan to insertion?
With optimized workflows, both Formlabs and NextDent systems can produce crowns ready for try-in within 2-4 hours, including post-processing time. However, actual chairtime efficiency depends heavily on practice workflow integration and staff experience with the specific platform.
What are the key integration requirements for existing practice management systems?
Most modern practice management systems can integrate with 3D printing workflows through STL file export capabilities. However, maintaining proper case tracking and patient data association may require additional workflow coordination tools or Intake.Dental for comprehensive patient documentation management throughout the digital production process.
Which platform offers better long-term scalability for growing practices?
Formlabs Dashboard provides superior fleet management capabilities for practices planning to scale 3D printing operations across multiple locations or high-volume production. NextDent offers more flexibility for practices requiring diverse material options or custom workflow integration with existing dental lab partnerships.
AI Content Disclosure: This article was created with AI assistance and reviewed for accuracy by our editorial team.
Medical Disclaimer: Information provided is for informational purposes only and does not constitute medical advice.