3D printers have become one of the most talked-about pieces of equipment in modern dentistry. Paired with an intraoral scanner, a chairside printer can produce models, surgical guides, splints and temporary restorations in-house, sometimes the same day. Prices have fallen and resins have improved, so more Australian practices are asking whether in-house printing makes sense for them.
This guide covers what dental 3D printers are used for, the real costs, the regulatory obligations in Australia, and how to decide whether it's right for your practice.
This article is general information for practice owners, not clinical, regulatory or legal advice.
Key takeaways
- Chairside printers can make models, surgical guides, splints, night guards, custom trays and temporary restorations, depending on the printer and resins.
- The business case depends on volume: how many printable items you currently send to a lab each month.
- Costs go beyond the printer: resins, wash and cure units, software, staff time and space.
- Practices that make devices for individual patients may have TGA obligations as manufacturers of custom-made medical devices.
- Start with simple, low-risk items like models and trays before moving to appliances or restorations.
What practices print
- Study and working models from intraoral scans
- Custom impression trays
- Surgical guides for implant placement
- Occlusal splints and night guards
- Temporary crowns and bridges
- Try-ins and mock-ups for cosmetic planning
- Aligner models for in-house clear aligner workflows
Some resins are marketed for definitive restorations. Check the material's intended use and evidence carefully before using it this way.
How the workflow fits together
- Scan the patient with an intraoral scanner.
- Design the item in CAD software, either in-house or through a design service.
- Print using a resin printer, most commonly SLA, DLP or LCD technology.
- Wash off excess resin.
- Post-cure in a UV curing unit, following the resin manufacturer's instructions exactly.
- Finish, check the fit and deliver.
Each step affects accuracy and safety. Skipping proper washing or curing can leave items under-cured, which can affect both strength and biocompatibility.
The business case
Work out your volume
List what you currently send to labs each month that could be printed in-house, such as models, trays, splints, guides and temporaries, and what you pay for each. That gives you a monthly figure to compare against the cost of printing.
Benefits
- Faster turnaround, in some cases the same day
- Lower cost per item for high-volume, simple items
- More control over remakes and adjustments
- Patient experience: fewer visits for some treatments
Costs
- Printer, plus wash and cure units
- Resins, which have a shelf life and are specific to each indication
- Design software or a design service subscription
- Consumables: build plates, tanks or films, isopropyl alcohol, gloves
- Staff time for design, printing, post-processing and quality checks
- Space and ventilation
For many practices, the lab remains the better choice for complex, aesthetic or definitive work, while printing handles simpler, high-volume items.
Regulatory obligations in Australia
Custom-made medical devices
When a dental practitioner makes a device such as a splint, guard or crown for a specific patient, they may be treated as the manufacturer of a custom-made medical device under TGA rules. Obligations can include:
- Meeting the relevant Essential Principles for safety and performance
- Keeping records about each device
- Reporting adverse events
- Submitting an annual report to the TGA about custom-made devices supplied
The TGA has published specific guidance for dental practitioners who make and adapt personalised medical devices. Read it before you start, and check your obligations with your indemnity insurer. Rules for personalised and patient-matched devices have changed in recent years.
Materials and equipment
The TGA treats a 3D printer used as manufacturing equipment differently from the device it produces. Resins used for intraoral devices should be suitable for the intended use, and some materials need to be included in the ARTG. Check each resin's regulatory status and instructions for use.
Workplace safety
Uncured resins can irritate skin and lungs. Use gloves, ensure good ventilation, store resins correctly and dispose of waste and isopropyl alcohol safely. Follow the safety data sheets for every product.
Getting started
- Start simple. Begin with models and custom trays, which carry low clinical risk.
- Choose a validated ecosystem. A printer, resins and curing settings that are validated to work together reduce errors.
- Write protocols for each item: resin, settings, washing, curing, checks and records.
- Train a champion, often a dental assistant or prosthetist, to own the workflow.
- Track results: cost per item, remakes and time saved.
Frequently asked questions
Is a 3D printer worth it for a small practice?
It depends on volume. If you send only a few printable items to a lab each month, the savings may not cover the costs and time. Calculate your volume first.
Do I need an intraoral scanner first?
Usually, yes. Printing works best with digital scans, though physical impressions or models can be scanned with a lab scanner.
Can printed items be used permanently in the mouth?
Only materials intended and validated for that purpose should be used, following the manufacturer's instructions. Many printed items are designed for temporary or limited use.
Next steps
Audit your lab invoices for the last three months and count the items you could print. Then read our intraoral scanner guide and what's worth adopting in 2027. While your clinical workflow goes digital, IntelliDent's AI agents can take routine calls and bookings off the front desk.