Dentsply Sirona Expands 3D Printing Portfolio with Primeprint Evolution: A Comprehensive In-Office Printing Solution for Restorations, Splints, and Surgical Guides

Dentsply Sirona has announced Primeprint Evolution, a significant expansion of its in-office 3D printing ecosystem. Building on the foundation of the original Primeprint system — which launched in 2022 and established a validated, closed-loop workflow for printing temporary restorations, occlusal splints, and orthodontic models — Primeprint Evolution introduces new hardware capabilities and an expanded resin portfolio that extends the system's clinical reach into permanent restorations and implant surgical guides.

New Hardware: Higher Resolution and Larger Build Platform

The Primeprint Evolution printer features a new 4K LCD light engine that delivers a native XY resolution of 35 microns — a substantial improvement over the 50-micron resolution of the original system. The build platform has also been enlarged, allowing the simultaneous printing of up to 16 single-unit restorations or four full-arch models in a single print run. Print speed has been improved through a new layer exposure algorithm that Dentsply Sirona says reduces average print time by approximately 25% compared to the previous generation, without compromising the dimensional accuracy that is critical for fit and occlusion.

Expanded Resin Portfolio: Permanent Restorations and Surgical Guides

The most clinically significant development in Primeprint Evolution is the introduction of two new validated resin materials. The first, Permanent Crown Resin (PCR), is a highly filled composite resin validated for the fabrication of permanent single-unit crowns and three-unit bridges. PCR has been developed to meet the mechanical and aesthetic requirements of long-term restorations, with a flexural strength of 180 MPa and a shade range of 16 VITA classical colours. The second new material, Surgical Guide Resin (SGR), is a biocompatible resin validated for the fabrication of implant surgical guides, enabling practices to produce patient-specific guides in-house on the day of surgery.

Validated Workflow and DS Core Integration

Primeprint Evolution operates within Dentsply Sirona's validated closed-loop workflow, meaning that all resin materials, print parameters, and post-processing steps are pre-configured and quality-assured by the manufacturer. The system integrates directly with DS Core, allowing clinicians to send designs from any connected CAD software — including Cerec, exocad, and 3Shape — directly to the printer queue. Post-processing is handled by the Primeprint Box, which automates washing and curing to ensure consistent results regardless of operator experience.

Clinical and Economic Implications

The addition of permanent crown capability to an in-office 3D printing system has significant implications for practice economics and patient experience. Practices that adopt Primeprint Evolution can now offer same-day permanent restorations without the capital investment of a milling unit, and at a material cost that is substantially lower than milled ceramic alternatives. Dentsply Sirona estimates that the per-unit material cost for a printed permanent crown using PCR is approximately 60–70% lower than an equivalent milled lithium disilicate restoration.

Primeprint Evolution is available for order globally from November 2026. Existing Primeprint owners will be offered a hardware upgrade path, and all new and upgrading customers will receive access to a dedicated Primeprint Evolution curriculum on DS Academy Campus, covering material selection, design guidelines, and post-processing protocols for each validated indication.