A story of innovation at Dental Designs

Digital dentures may feel like a new technology, but the truth is they have been evolving for more than 10 years.

At Dental Designs, we’ve been part of that journey from the beginning.

For decades, dentures were created using traditional techniques — pouring stone models, hand-setting teeth in wax, processing acrylic, and finishing each case by hand. Many of our removable technicians have been perfecting this craft since the 1980s, and we still take great pride in that work today.

But as dentistry moved toward digital workflows and patients began expecting faster solutions with stronger materials, the industry started searching for a new way to produce dentures.

That’s when the idea of digital dentures began.

The Early Experiments

The first attempts started with milling PMMA.

The challenge was that early CAD software didn’t actually have tools for designing dentures.
Technicians had to manipulate the software and design dentures as if they were bridges with gingiva. It required creativity, patience, and a little bit of digital wizardry.

The results were exciting, but they weren’t perfect. Dentures milled from solid tooth-colored PMMA had to be stained by hand to create the appearance of gingiva. It worked — but it wasn’t the ideal solution.

Still, it proved that digital dentures were possible.

The 3D Printing Breakthrough

Then came 3D printing.

For the first time, labs could print pink bases and tooth-colored arches that could be bonded together to resemble traditional dentures. At the same time,
CAD software companies finally released dedicated tools for digital denture design.

Dental Designs jumped in immediately.

We invested in printers, software, and training — even sending our traditional removable technicians to learn how to become digital designers.

When our first denture finished printing, our team gathered around the printer to watch it complete the process. It felt like witnessing the beginning of something big.

Because it was.

Then Came the Growing Pains

The designs looked great.
The printers worked beautifully.
The aesthetics were impressive.

But the materials were not ready.

The first generation of printed dentures were simply too fragile, and many labs across the industry experienced failures. Dental Designs included.

It was similar to the early days of zirconia crowns — strong ideas, but materials that still needed time to evolve.

So the industry kept pushing forward.

What Changed Everything

The answer was simple.

Materials.

Today’s printed denture materials have dramatically improved flexural strength, durability, and aesthetics. Combined with modern design software and advanced printers, digital dentures have reached a point 
where they can now rival — and in many cases exceed — traditional dentures.

Dental Designs has stayed committed to this evolution every step of the way.

The Next Chapter: Digital Flex Partials

And now the next advancement has 
arrived.

Digital Flex Partials.

While this technology has existed for 
years, we intentionally waited until the materials and processes met the 
standard we expect for our doctors and 
patients.

After months of internal testing, we are proud to now offer
digitally printed flexible 
partial dentures.

The advantages are clear:

• Stronger and more consistent materials
• Improved production accuracy
• Fewer processing variables
• Faster turnaround

Just like crowns, full-arch restorations, splints, and dentures before them, flex partials are entering the digital era.

And the timing is finally right.

Thank You for Growing With Us

To the doctors who have been part of this journey with us — thank you.

Your willingness to evolve alongside us has helped move dentistry forward.

And if you tried digital dentures years ago and were not satisfied, we encourage you to take another look today.

The technology has changed.
The materials have improved.
And the future of digital removable is here.

If you’d like to learn more about Digital Dentures or Digital Flex Partials, our Dental Designs removable team would be happy to connect.