How to Process Working Models before Printing?

In our previous article, we introduced the preparation methods for orthodontic models. This time, we will discuss another commonly used model type in dentistry—working models. New users can refer to the Primer tutorial, What to Do Before Model Preparation in CHITUBOX Dental?, to learn how to complete initial settings after launching the software, including printer and material selection, print parameter configuration, and model import. This article will cover pre-print processing techniques for working models, including considerations for both automated and manual workflows. s.

Automatic Processing

Working models are dental casts used for fabricating restorations. Their shape and processing methods are nearly identical to orthodontic models. However, many working models require printing dies—individual prep models that can be detached from the working model. Dies are typically small in size and prone to deformation or breakage if hollowed, so solid printing is recommended. When using CHITUBOX Dental’s automated processing function, users should avoid selecting dies and only check the working models. In the software, the corresponding application type for working models is the Restorative Model. Before processing, ensure the application type in the configuration page is set to Restorative Model.

CHITUBOX Dental’s automated workflow for working models defaults to including orientation, hollowing, drilling, and layout. Users only need to import the model, select the working models, and click the Auto Process button to complete the processing. However, as mentioned earlier, if dies require solid printing, supports must be added. Printing dies directly on the build plate may cause over-curing at the base, preventing proper seating with the working model. Therefore, thin supports should be added to the dies separately.

If users wish to change the default workflow, they can enter the configuration page, click the Settings button next to Enable Automated Processing at the bottom left, and adjust the steps or their detailed settings.

Manual Processing

The manual processing sequence for working models follows the same steps as the automated workflow. However, if the imported model is already hollowed, users can skip hollowing and proceed directly to filling. If unsatisfied with the wall thickness or internal structure, users can perform solid filling first and then re-hollow the model. The specific order depends on user requirements. Below is a detailed breakdown of how to process working models step by step.

Orientation

Since working models, orthodontic models, and study models all share a dental cast structure, their orientation method is identical. The model should lie flat on the build plate with the base fully adhered to the platform to avoid supports affecting the accuracy of the gingival area and tooth margins. This method also minimizes print height, reduces layer count, and shortens printing time.

CHITUBOX Dental offers one-click orientation for multiple models. Just select the Rotate tool from the left toolbar and click Auto Orientation. Whether orienting the entire working model or dies, CHITUBOX Dental aligns their bases with the platform to minimize layer line impact on precision.

Please note that, to eliminate the need for supports, the model base must be uniformly leveled and fully adhered to the build plate. If the base is uneven, use CHITUBOX Dental’s Cut function to trim it, ensuring a flat and stable fit.

Hollowing & Filling

After orientation, the next step is hollowing or filling. If the imported model is solid, it can be hollowed directly with a recommended wall thickness of 1–2mm, and the internal structure can be filled with a hive or grid pattern to enhance strength and prevent deformation. If the model is hollowed, users can directly fill it with a hive/grid structure or select the bottom fill only mode. If unsatisfied with the wall thickness or internal structure of a hollowed model, users can first apply solid fill, then reconfigure the wall thickness and structure for re-hollowing.

Hive and grid structures are recommended due to their through holes and dome designs. Through holes help balance internal and external pressure of models during printing, reducing model vibration during plate movement while facilitating resin flow back into the vat. This minimizes material waste and post-curing time. Dome structures are automatically generated under overhangs, eliminating the need for internal supports.

A critical consideration in this step is that the model must form an enclosed cavity with the build plate for successful hollowing or filling. For working models with open tooth sockets, the design software must separate the perforated areas from other internal areas. And dies, being small, can skip hollowing.

For the bottom fill only function, users can enable it in the Hollow or Filling menu. This feature increases the model’s contact area with the build plate to prevent detachment during printing while using less material to maintain strength for models with small internal cavities.

Drilling

CHITUBOX Dental’s drill function supports batch drilling and offers semi-circular hole designs for models printed flat on the plate. Users only need to set the hole count and height.

It should be noted that: Hole Count refers to the number of holes per model, not the total across all models.

Position Height is the distance from the hole center to the build plate. For semi-circular holes, set this to 0mm; for full circles, the height should be equal to or greater than the hole radius.

Bridge Generators

Full-arch working models are prone to warping due to their shape. To ensure long-term stability, bridge generators can effectively control post-print deformation. CHITUBOX Dental allows users to auto-generate them or manually place them, with multiple shape and size options for flexible customization.

Supports

Separate supports must be added to the dies. As mentioned above, the initial layers of resin prints are bigger than usual because of over-curing. If dies are printed directly on the plate, the base may deform, preventing proper seating with the working model. So, when you process the working models with dies, remember to add support for the dies. Given their small size, dies typically only require thin supports to avoid compromising accuracy.

Layout

Finally, arrange the models for printing. CHITUBOX Dental’s nested automatic layout function enables tighter layouts, reducing print cycles and total printing time.

After completing these steps, carefully check whether all parts of the model are intact and verify printer/material parameters. Once confirmed, click "Slice" to enter the preview interface where you can view each layer of the model slice. Save the file locally or to a storage device for transfer to the 3D printer. For network-enabled machines, users can click "Send to Printer" to directly transmit the file and initiate printing.

The above covers our recommended workflow for processing working models in CHITUBOX Dental. If you have alternative insights, feel free to share them at marketing@dental.chitubox.com.