Asiga Workflow: Splints and Night Guards

Splints and night guards are common dental applications for Asiga 3D printers. Producing accurate occlusal appliances requires careful material selection, print orientation, support placement and post-processing.

This guide explains the recommended workflow for printing splints and night guards using Asiga printers, including considerations for VOCO V-print Splint Clear and other validated dental appliance materials.

This article covers how to use Asiga printers to produce:

• Occlusal splints
• Night guards
• Bruxism appliances
• Bite appliances
• Orthodontic retention appliances where compatible

1. Select Materials

Use a validated dental splint resin. The material’s instructions for use (IFU) must specify splints as an indication.

Recommended materials:

• Flexible splints: VOCO V-Print Splint Comfort Clear 1kg | XYZ Dental
• Hard splints: VOCO V-Print Splint Clear 1kg | XYZ Dental

For any material, the instructions for use (IFU) must specify splints as an indication to be used. Always follow the resin manufacturer’s IFU for storage and curing protocol.

Material selection should consider:

• Strength
• Flexibility
• Wear resistance
• Biocompatibility requirements
• Post-processing workflow

2. Tray Considerations

Select a tray based on the desired surface finish for your printer. Asiga printers come packaged with a Universal build tray (or Endurance for Asiga Ultra), ideal for surface matte finish. The UltraGLOSS trays are highly recommended for splints since they give a glossy surface finish.

Matte surface finish

• Universal or Endurance Trays
  • 1L MAX Universal Build Tray | XYZ Dental
  • 2L Ultra Endurance™ Build Tray | XYZ Dental
  • 2L PRO 4K Endurance Build Tray | XYZ Dental
  • 5L Ultra Endurance build tray | XYZ Dental
• Low-Force Trays (Ideal for flexible splints)
  • 1L MAX Low Force Build Tray | XYZ Dental

Glossy surface finish

• UltraGLOSS Trays
  • Max UltraGLOSS LIFT™ Build Tray | XYZ Dental
  • Ultra Build Tray 2L – UltraGLOSS | XYZ Dental

3. Load the Splint Job in Asiga Composer

Before starting, prepare a splint design and export from design software as a 3D mesh file (.STL, .PLY, .SLC, .STM). Check the occlusal anatomy, wall thickness and that the geometry is not broken.

Next, download the material configuration file if this is the first time:

1. For VOCO materials, login on your Asiga account at Asiga Material Library: VOCO.
2. Download the material configuration file (.ini) for your splint material.
3. On Asiga Composer, upload the .ini file with Build Properties > Material Profile Settings > Import Material Profile

For an in-depth guide to import materials, see this article: Import Materials into Asiga Composer | XYZ Dental

Asiga Composer features are explained in detail in this article: Asiga Composer: How to Create a Print Job | XYZ Dental

Select the Build Properties for your new build.

1. Select your material, layer thickness and build tray. Layer thickness is recommended to be 0.100 mm or lower, depending on your accuracy and production needs.
2. Add parts into Asiga Composer by selecting the splint 3D mesh files.

Orient the Splint and Generate Supports

Correct orientation is important for maintaining occlusal accuracy, surface quality and strength. Supports should be minimised for accuracy and reduced post-processing time.

Here are some rules for orienting splints:

• Avoid supports inside the fitting area and occlusal surface
• Few supports on visible area
• Minimise overhanging area

To achieve the above, it is recommended to face the splint diagonally, lingual side down (towards the build platform, leaning towards the occlusal side. When generating the supports, they should contact the lingual side of the front teeth.

If there are supports in the fitting area or occlusal surface, remove them with the tool under Advanced Settings of the “Generate Supports” menu. Check that there are no large overhangs and add supports where needed.

4. Print

Prepare the material and tray specified in the job. Mix the material with silicone spatula. Start the print job on the printer interface.

5. Post-Processing

Ensure that you follow the material IFU for exact washing and curing instructions. After printing:

1. Remove the splint carefully.
2. Wash with IPA.
3. Remove supports and grind the bumps to give the surface a smooth finish.
4. Wash with IPA again in a separate wash.
5. Complete required curing.

Correct post-processing is essential for appliance strength and accuracy.

6. Quality Control

Inspect:

• Internal fit
• Occlusal contacts
• Appliance thickness
• Surface finish
• Defects or warping

Record successful workflows for repeat production.

If splint or night guard printing issues continue after troubleshooting, contact support at XYZ Dental for assistance.

Links

Asiga Composer: How to Create a Print Job | XYZ Dental

Import Materials into Asiga Composer | XYZ Dental

VOCO V-Print Splint Comfort Clear 1kg

VOCO V-Print Splint Clear 1kg