Beyond the Wax: How Dual Resins Built the Perfect, Seamless Denture
By Brittany Mitchell
The Challenge:
Beyond Analog Limitations
At Advance Dentistry in Cincinnati, our commitment is always to provide patients with restorations that are precise, comfortable, and durable. Dentures have always been the most labor intensive appliances produced in a dental lab. Traditional methods involve fire, wax setups, flasking, boiling out, and multiple layers of manual work that leave room for more human error and are inherently prone to dimensional instability, and require extensive fit adjustments chairside, leading to frustration for both doctors and patients. By introducing digital dentures into my workflow. I’ve been able to achieve a new level of precision and creativity. As our workflow evolved, we needed a system smart enough to handle the challenge of printing the base and teeth separately,
The Solution:
Asiga Ultra and Dual Resin Workflow
Our solution was integrating the Asiga Ultra 3D printer alongside the dedicated Asiga dental resins: DentaBASE for the pink gingiva, and DentaTOOTH for the teeth. This two-part approach allows us to leverage the specific mechanical properties of each material, ensuring the final prosthetic is both strong and aesthetic. Our streamlined workflow is as follows:
Digital Design: After taking intraoral scans and bite records, the dentures are designed in our 3Shape CAD software. The gingival base and the denture teeth
are designed as separate STL files.
Dual Printing: We utilize the Asiga Ultra’s precision to print the components:
DentaBASE (Natural Pink): This material is chosen for its strength and natural color, which is essential for the foundation of the denture.
DentaTOOTH (Vita Shade): Simultaneously, or immediately after, we print the individual denture teeth using DentaTOOTH resin, selecting the appropriate Vita shade (usually A2 or A3) based on the patient’s request. DentaTOOTH is formulated for high wear and stain resistance, giving the patient a durable, long-lasting smile.
Post-Processing and Integration: After printing, the parts are washed and post-cured according to the validated Asiga protocol. The printed DentaBASE and DentaTOOTH components are then precisely bonded together using the base resin. Because DentaBASE is engineered for excellent adhesion characteristics when bonding DentaTOOTH, the final fit is seamless and robust.
The Result:
Precision, Speed, and Patient Satisfaction
Switching to the Asiga Ultra and the DentaBASE/DentaTOOTH system has fundamentally changed our output here in Cincinnati. First, reproducibility is guaranteed. The fit is exceptionally accurate compared to flasked acrylic, minimizing the chairside adjustments that used to eat up doctors time. Second, the aesthetics and durability are superior. The DentaTOOTH resin gives us high-quality dentition that resists wear, while the DentaBASE provides a resilient, stain-resistant base. Ultimately, the digital workflow has drastically reduced the time spent in the lab and in the chair. We can manufacture a custom denture with predictable precision, faster than ever before. For patients, this means receiving dentures that not only look natural but also fit comfortably. For dentists, it means reliable outcomes with minimal chairside adjustments. And for me, as a dental technician, it means reclaiming valuable time while elevating the artistry and precision of my work. I spend less time fighting materials and more time focusing on the seamless finish.
About the Author
Brittany Mitchell is a skilled Dental Laboratory Technician with over six years of hands-on experience in removable and digital dentistry. She began her career in dentistry at the front desk, where her artistic talent and eye for detail were quickly recognized by a mentor who introduced her to the dental laboratory field. Since then, Brittany has refined her craft and currently serves as a Digital Removable Technician at Advance Dentistry.
Passionate about both precision and artistry, Brittany is dedicated to advancing the field of dental technology while fostering a culture of support and collaboration. She is the founder of The Balanced Bench, a growing platform on Instagram dedicated to raising mental health awareness for dental laboratory technicians worldwide. Through this initiative, she advocates for balance, resilience, and community in an industry often overlooked for its emotional and creative demands.
Brittany’s work is guided by her belief in empowerment. Especially for technicians who are just starting or thriving in the dental lab profession. By blending her technical expertise with her commitment to mentorship and advocacy, she strives to make a lasting impact on both her patients’ smiles and her colleagues’ well-being.
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