As the demand for digital dental solutions grows, dental labs are looking for innovative ways to streamline production, reduce labor and optimize workflows. For Advanced Dental Technologies (ADT), a mid-size dental lab based in Stoneham, Massachusetts, the solution comes in the form of Stratasys’ PolyJet 3D printing technology.
Under the leadership of president Dany Karam, ADT specializes in high-quality dental restorations, including crowns, bridges, implant models, and surgical guides. By adopting PolyJet technology with the Stratasys J3 DentaJet, ADT has transformed its operations, reducing labor-intensive processes and freeing up its dental technicians to work at the top of their trade.
ADT’s journey toward digital transformation began many years ago, as intraoral scanning began to replace traditional wet impressions in the dental industry.
“We saw a significant shift in how cases were being submitted by our clients,” says Karam. “Intraoral scanning grew to become a major part of our workflow, with 60-80% of our cases now coming in digitally, depending on the season.”
While this shift towards digital dentistry offered the potential for faster, more precise results, it also created new challenges in production capacity and workflow efficiency.
At first, ADT relied on multiple entry-level 3D printers to handle the increasing volume of digital cases. But Karam soon realized that this approach led to workflow bottlenecks and inefficiencies.
“It may seem logical to scale up by using several low-cost printers, but the labor involved in managing multiple machines was overwhelming,” Karam explains. “Each printer required individual attention for tasks like resin swaps and post-processing, which ate up time and resources.”
In fact, with the J3 DentaJet, ADT went from producing just 48 models across three non-Stratasys printers to nesting up to 108 models, soft tissue pieces, and surgical guides in a single print run. This capability nearly increased ADT's production sevenfold, significantly reducing manual labor and allowing technicians to focus on higher-value tasks.
To overcome these challenges, ADT invested in the Stratasys J3 DentaJet, a multi-material 3D printer designed specifically for dental applications.
“We needed a printer that could handle multiple materials in a single print job while freeing up labor and reducing both pre- and post-processing time,” says Karam. The J3 DentaJet offers precisely that. With its ability to print implant models, surgical guides, and gingiva masks simultaneously, the printer allows ADT to consolidate production of multiple applications into a single, efficient process.
“We chose the J3 because of its multi-material capabilities, its large build plate in a compact footprint, and the fact that it prints parts that are fully cured during the printing process,” says Karam.
This last feature eliminates the need for separate curing units and makes post-processing as simple as a water rinse, significantly reducing labor and consumables costs.
“We used to spend hours cleaning models with alcohol, which needs to be handled and disposed of carefully and is expensive, especially during the pandemic when it was also hard to find. Now, everything is done with water which is safer, less expensive, and always available,” says Karam.
The J3’s ability to print biocompatible materials for multiple applications at once was a game-changer for ADT. Whether the lab is producing implant models, custom trays, or surgical guides, they can complete jobs without manual interventions, even running them completely unattended overnight, freeing up technicians to focus on higher-level tasks throughout their workday that directly contribute to business growth.
Before investing in the J3 DentaJet, ADT’s production workflow required constant supervision. A technician was responsible for setting up prints every 45 minutes to an hour, managing material changes, and overseeing each machine individually.
“Before, we had one person who spent their entire day just managing prints,” Karam recalls. “With the J3, we can now set up the printer to run overnight, and it prints everything we need perfectly – it’s all finished and ready for us by the time we come in the next morning.”
Overnight printing has significantly boosted ADT’s efficiency. By scheduling prints to finish at 8 a.m., when the lab opens for the day, Karam’s team can immediately begin post-processing and move on to the next batch of jobs.
We went from having someone manage printers all day to that person now handling design tasks and higher-level responsibilities,” Karam says. “This technology elevated our employees’ roles and allowed us to better utilize our staff.”
In fact, the efficiency gains afforded by the J3 DentaJet have freed up nearly 50% of each technician’s day.
In addition to reducing labor demands, the J3 DentaJet also improved production accuracy. The fully cured prints produced by the PolyJet process mean that ADT no longer has to worry about shrinkage or loose-fitting parts—issues that often occurred with their previous DLP printers.
“The parts come out ready to use, with no need for additional curing or post-processing steps,” Karam notes. “This has saved us time and improved the quality of our final products.”
The financial impact of the J3 DentaJet has been significant for ADT. In labor alone, ADT has saved over $41,000 annually by consolidating production into a single printer, reducing the need for multiple machines and eliminating labor-intensive manual steps.
“What we save in labor and consumables more than pays for the printer itself in less than a year,” says Karam.
Additionally, ADT now saves more than $100 per build in consumables costs, further boosting their bottom line.
As ADT continues to grow, Karam is confident that the J3 DentaJet will scale with the lab’s increasing production demands.
“One of the reasons we invested in this printer was its ability to handle future growth,” he says. “Whether we’re expanding into new applications or simply increasing our volume, the J3 can meet those needs without requiring additional labor or resources.”
The versatility of the PolyJet technology also gives ADT the flexibility to offer a wider range of services to its clients.
“We can produce everything from surgical guides to orthodontic models, soft tissue simulations, and try-ins all in one print job,” says Karam. “It’s allowed us to diversify our offerings and keep up with the changing needs of our clients.”
A key feature that contributes to ADT’s success with the J3 DentaJet is the integration of GrabCAD Print software, allowing ADT to significantly streamline its workflow, especially in managing complex jobs with multiple materials.
“GrabCAD is integral to how we run our jobs. The software automates nesting, so we can simply load cases into the system and it arranges them in seconds for optimal efficiency,” Karam explains.
This automation allows ADT to prepare jobs faster, eliminating the manual labor that was previously needed to configure multiple prints.
GrabCAD also provides real-time notifications and remote monitoring, empowering technicians to keep tabs on their printing process from anywhere.
“The ability to get notifications when a job is done or if something needs attention is invaluable,” says Karam. “It means we can focus on other tasks without constantly checking on the printer.”
By automating much of the pre-print setup and allowing the team to monitor jobs remotely, GrabCAD has further reduced the manual labor needed in ADT’s production process, helping the lab maintain high efficiency and consistent results.
While the advanced features of the J3 DentaJet were a major factor in ADT’s decision to invest, Karam also emphasizes the importance of post-purchase support.
“When you’re running a dental lab, you quickly learn that support is critical,” Karam says. “You need to know that if something goes wrong, you have a partner who can help you get back up and running as quickly as possible.”
Stratasys’ Dental Priority program provides ADT with the ongoing support they need to maintain smooth operations.
“The technical support from Stratasys has been excellent,” Karam says. “We have access to same-day support from dental experts, and if anything goes wrong, they can often resolve the issue within hours.”
In addition to technical support, Stratasys offers proactive maintenance and advanced real-time monitoring to ensure that the J3 DentaJet continues to operate at peak performance.
“When you’re considering a major investment like a 3D printer, it’s not just about the technology itself—it’s about the long-term relationship with the company that makes it,” Karam says. “Stratasys has been an ideal partner every step of the way, from installation to ongoing maintenance and support.”
For other dental labs considering their next 3D printer, Karam offers a few key pieces of advice. First, he recommends looking beyond the initial cost and focusing on the long-term return on investment.
“It’s easy to be tempted by lower-cost options, but you have to factor in the labor savings, workflow efficiency, and reliability that come with a more advanced printer like the J3 DentaJet,” he says.
Karam also emphasizes the importance of considering future growth when choosing a printer.
“You want a printer that can grow with your lab, not something you’ll outgrow in a few years,” he advises. “The J3 DentaJet has the flexibility to handle whatever applications and volume we may need in the future, which gives us confidence that we’ve made a smart investment.”
Finally, Karam encourages lab owners to prioritize post-purchase support.
“Having a reliable partner for maintenance and troubleshooting is just as important as the printer itself,” he says. “Stratasys has been there for us whenever we’ve needed them, and that’s made a huge difference in our ability to keep production running smoothly.”
Find out how PolyJet technology and the DentaJet Series of 3D printers can save your lab time and labor while increasing capacity and quality? Schedule time to speak with one of our dental 3D printing experts today.
