formlabs Form 3BL Dental LT Clear V2 Resin User Guide

: June 1, 2024
: formlabs

Table of Contents

Specific Manufacturing Considerations
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MANUFACTURING GUIDE
Dental LT Clear V2 Resin

Dental LT Clear V2 Resin is a light-curable polymer-based resin designed for the fabrication of biocompatible, long-term use, removable dental and orthodontic appliances such as occlusal splints, night guards, mouthguards, and/or bleaching trays by additive manufacturing. This Manufacturing Guide will give equipment, printing and post-processing recommendations and requirements to ensure the correct and safe usage of this material.

Specific Manufacturing Considerations

Dental LT Clear V2 Resin specifications have been validated using the hardware and parameters indicated below. For biocompatibility compliance, validation used a dedicated resin tank and mixer, build platform, wash unit and post- processing equipment that were not mixed with any other resins.

Hardware:
a. Formlabs 3D Printer: Form 2, Form 3B/3B+, Form 3BL, Form 4B
b. Print Accessories: Formlabs Build Platforms, Formlabs Resin Tanks
Software:
a. Formlabs PreForm
Printing Parameters:
a. Part Orientation: Intaglio surface facing away from the build platform at a 0 – 40° tilted angle
b. Layer Thickness: 100 μm
c. Part Thickness:
• Occlusal Surfaces: 2 mm minimum
• Walls: 1 mm minimum
Recommended Post-Processing Equipment and Accessories:
a. Formlabs Processing Accessories: Form Auto, Resin Pumping System
b. Formlabs Validated Wash Unit: Form Wash, Form Wash (2nd Generation), Form Wash L, Ultrasonic Wash Unit
c. Formlabs Validated Cure Unit: Form Cure, Form Cure L, Fast Cure

A. PRINTING

Shake cartridge: Shake the cartridge before every print job. Color deviations and print failures may occur if the cartridge is shaken insufficiently.
Set up: Insert resin cartridge into a compatible Formlabs 3D printer. Insert resin tank and attach mixer to the tank.
Printing:
a. Prepare a print job using PreForm software. Import desired part STL file.
b. Orient and generate supports.
c. Send the print job to the printer.
d. Begin print by selecting a print job from the print menu. Follow any prompts or dialogs shown on the printer screen. Printer will automatically complete the print.

B. PART REMOVAL
Remove the build platform from the printer. To remove parts from the build platform, wedge the part removal tool under the printed part raft, and rotate the tool. Formlabs Build Platform 2 or Build Platform 2L may be used for easy, tool free removal. For detailed techniques visit support.formlabs.com.
C. WASHING
Place the printed parts in a Formlabs-validated wash unit with 99% Isopropyl Alcohol.

Form Wash, Form Wash (2nd Generation) – High speed, or Form Wash L:
a. Wash for 15 minutes or until clean in Form Wash or Form Wash L.
b. Remove parts from the wash unit and soak in fresh Isopropyl Alcohol for 5 minutes.
c. If parts do not appear clean after washing, consider replacing used Isopropyl Alcohol in the wash unit with fresh solvent.
For Form Wash (2nd Gen), High speed settings are validated for use.
Ultrasonic Wash Unit:

NOTE: Using Isopropyl Alcohol in an ultrasonic bath presents a risk of fire or explosion. When using an ultrasonic wash read and follow all safety recommendations from the ultrasonic wash manufacturer.
a. Use clean 99% Isopropyl Alcohol for each wash.
b. Place parts in a secondary disposable plastic container or plastic resealable bag then fill with 99% Isopropyl Alcohol, ensuring parts are fully submerged.
c. Place the secondary container in the ultrasonic unit water bath and sonicate for 2 minutes or until clean.*

*Washing efficacy depends on the ultrasonic unit size and power. Formlabs testing was conducted with ultrasonic units at 36 W/L or higher.

D. DRYING

Remove parts from Isopropyl Alcohol and leave to air dry at room temperature for at least 30 minutes.
NOTE: Dry times can vary depending on the design of parts and ambient conditions. Do not let parts sit in Isopropyl Alcohol for longer than needed.
Inspect printed parts to ensure that parts are clean and dry. No residual solvent, excess liquid resin or residue particles should remain on the surface before proceeding to subsequent steps.
If the residual solvent is still present, dry parts longer. If resin residue is still visible, rewash parts until clean and dry.

E. POST-CURING
Place the printed parts in a Formlabs-validated post-curing unit and cure for the required time.

Form Cure or Form Cure L:
a. Cure for 60 minutes at 60 °C
b. Allow the Form Cure or Form Cure L unit to cool down to room temperature between cure cycles.
Fast Cure:
a. Cure for 6 minutes at Light Intensity 5
b. Allow the Fast Cure unit to cool for at least 10 minutes between cure cycles.

F. SUPPORT REMOVAL & POLISHING

Support marks can cause abrasion if not removed and polished. Remove supports using a cutting disk and handpiece, cutting plier, or other appropriate finishing tools.
Polish the printed appliances using typical dental polishing methods prior to patient use.
Inspect the parts for any cracks. Discard if any damage or cracks are detected.

G. CLEANING & DISINFECTION

Fully post-processed parts can be cleaned using a dedicated soft toothbrush with neutral soap and room-temperature water. Do not use toothpaste or any other cleaning products on parts printed with Dental LT Clear V2 Resin.
The appliances may be cleaned and disinfected according to facility protocols. Tested disinfection method: soaking the finished appliance in fresh 70% IPA for 5 minutes. Do not leave the part in the alcohol solution for longer than 5 minutes.
After cleaning and disinfection inspect the part for damage or cracks to ensure that the integrity of the designed part meets performance requirements. Discard if any damage or cracks are detected.

H. HAZARDS, STORAGE & DISPOSAL