Desktop Health Flexcera Base and Flexcera Base Ultra+
Flexcera™ Base is now available to produce denture bases. The material is a durable, biocompatible resin that produces premium dentures.
Flexcera™ Base Ultra+ is available to produce full and partial denture bases.
There are two options to properly prepare your denture bases for printing: manually or automatically using the Auto Nest Dentures feature.
Auto Nest Dentures is only available for full denture bases. It does not work for partial denture bases.
Review instruction for manual preparation first, so that the you understand what a properly oriented and supported base looks like.
Flexcera Base is compatible with the AO Polishing Cassette.
This protocol sheet applies to both Flexcera Base and Flexcera Base Ultra+.
There are two options to properly prepare your denture bases for printing:
This guide provides instruction for manual preparation first so that the technician understands what a properly oriented and supported base looks like.
See Denture Bases Automation Guidelines for specific instructions on using APP to automatically orient, support, layout and queue projects for printing.
- Click Support tab or Shift + S in the top bar.
- Select the part you want to support.
- Under Position, select Above Platform to lift parts off the platform.
- Select the part to be supported.
- Orient the camera so that the overhangs are clearly visible.
- Check that Patch is selected.
- Click on each large overhang to select it. A green patch will appear over each overhang. Repeat until all the large overhangs are selected.
- Under Support Attributes → Primary Support Type, select Fence.
- The other Support Attributes should remain their default values.
- Click Generate All to create the support fences.
- Select Fence tool.
- Click a series of points in an area of overhang to define the fence.
- Target long, narrow overhangs and small overhangs.
- Click ESC key to finish adding points to a polyline.
- Hold down E key to reposition points.
- Click off of the part and drag a box to select points. Press Backspace to delete.
- Click a polyline to select for editing.
- Support Attributes should remain their default values.
- Click Generate All to create the support fences.
- Repeat steps 1 - 5 as needed.
- Alternately, you can add multiple polylines as needed and then click Generate All to create multiple fences at once.
Review Supports in Printer UI course for more information.
This information applies to both Flexcera Base and Flexcera Base Ultra+.
Connect to Printer
- Open browser.
- Carbon recommends the latest version of Google Chrome.
- Carbon recommends bookmarking this site for later use.
- If you are not automatically logged in, enter your email and password and click Log in.
- If you have multiple printers, click the printer that you wish to use.
Open Your Denture Files
Once you have chosen the printer, you must create a new project.
- Click NEW PROJECT.
- You can also drag your files from a file browser window and drop it on top of the NEW PROJECT icon.
- Enter a new Project name.
- Leave Auto nest dentures OFF.
- Only use Encrypt project if you want to require a password to access the project.
- Note: Carbon cannot provide support for encrypted projects.
- Drag and drop your files into the dotted box or click Browse your files and select them in a file browser window.
- Click Create.
- After a few moments you will see the main printer interface with your dentures on the platform.
- Click the resin drop down menu in the top left corner of the menu bar.
- Select Flexcera Base or Flexcera Base Ultra+ as needed.
Proper orientation of bases is critical to achieve the required accuracy. Failure to orient denture bases according to these instructions may impact accuracy and part quality.
LOWER DENTURE BASE
- Oriented vertically at a 90 degree angle.
- Anterior touches the platform.
UPPER DENTURE BASE
- Oriented vertically at a 90 degree angle.
- Anterior touches the platform.
Step 1: Minimize Footprint
Minimize footprint
- Click Orient or press Shift + o in the main bar in the printer software.
- Click Minimize Footprint button. This will orient the base roughly perpendicular to the platform.
Step 2: Tilt into Position
- Make sure the denture is selected.
- Click on the axis loop and rotate the denture into place.
- The anterior of each denture should be touching the platform.
For both the lower and upper denture bases, rotate 90 degrees.
Your denture bases are now properly oriented and ready to be supported.
Denture bases are supported using two tools:
- The Patch tool automatically creates a field of supports. It is used to create supports for the anterior facial region.
- The Fence tool is used to manually place a thin wall of supports. Fences are placed along the lingual and buccal edges for lower dentures and along lingual edges on upper dentures. In some cases, fences are needed on bars or the posterior edges of upper dentures.
Note: Do not put supports on intaglio surfaces.
Before starting, optimize the interface for adding fences.
- Click Toggle Platform button in the lower tool bar or press the B key to hide the platform. This will enable better visibility during fence creation.
- Click Overhang Detection button (V key) to find areas that need support.
- Set the angle to 40-60 degrees.
- Click Supports in the dark gray bar.
- Under Part Position, select Above to create room between the platform and the part.
- Click the Manual tab and select Patch.
- Leave the Support Attributes at the default values.
Support Anterior Area and edges with Patch Supports
The outer anterior area is typically a large overhang that requires dense fence supports. This area must be supported with the Patch support tool. This is required for both upper and lower dentures. The example pictured is an upper denture.
- While in the Supports menu, click the Manual tab and select Patch.
- Click in the large overhang on the anterior of the upper base. A green patch will appear.
- Under Support Attributes click Primary Support Type and select Fence.
- In the Spacing box, spalce supports between 3-5 mm.
- Scroll down to the bottom of the Supports menu and turn Boundary Fence on.
- Adjust the Overhang slider untile the highlighted overhang areas are covered by the green patch. Typically this will be between 40 and 60 degrees.
- Click Generate all.
See a demonstration of using the Patch tool in the video below.
Inner edge of lower denture
The inner edge of the lower denture requires manual fence supports:
- Click a series of points along the edge to define the fence.
- Click Esc key on the keyboard to end a fence and begin another.
- Hold down the E key and click with the mouse to reposition points.
- Click Generate All to create the fence geometry. This may take a few minutes.
Be sure to set Part Position to ABOVE before you begin adding supports.
Error: Support couldn't be added
Sometimes an error will occur when you try to generate a new fence.
If this happens the points will turn pink and an error messsage will appear.
Try making multiple shorter fences or try adding the fence in a slightly different place.
Posterior edge of upper denture
Although upper dentures do not have an inner edge, they may require supports along the posterior edge to ensure proper accuracy.
Lower denture crossbars
- Click a series of points along the bottom surface of the bars to define the fence.
- Click Esc key on the keyboard to end a fence and begin another.
- Hold down the E key and click with the mouse to reposition points.
- Click Generate All to create the fence geometry. This may take a few minutes.
Use the images below as a reference for well supported upper and lower dentures. Click the images to zoom in.
This information applies to Flexcera Base Ultra+
Connect to the printer using your web browser:
- Open browser.
- Carbon recommends the latest version of Google Chrome.
- Carbon recommends bookmarking this site for later use.
- If you are not automatically logged in, enter your email and password and click Log in.
- If you have multiple printers, click the printer that you wish to use.
Open Partial Denture Base Files
Once you have chosen the printer, you must create a new project.
- Click NEW PROJECT.
- You can also drag your files from a file browser window and drop it on top of the NEW PROJECT button.
- Enter a new project name.
- Under Resin, select Flexcera Base Ultra+.
- Toggle Auto nest dentures OFF.
- Only use Encrypt project if you want to require a password to access the project.
- Note: Carbon cannot provide support for encrypted projects.
- Drag and drop your files into the dotted box or click Browse your files and select them in a file browser window.
- Click Create.
- After a few moments you will see the main printer interface with your partial dentures on the platform.
In the resin menu, double check that Flexcera Base Ulta+ has been selected.
Proper orientation of bases is critical to achieve the required accuracy. Failure to orient denture bases according to these instructions may impact accuracy and part quality.
Cameo surfaces face the platform. In other words, intaglio surfaces face away from platform.
Oriented parallel with platform
Manually orient partial denture
- Click Orient or press Shift + o in the main bar in the printer software.
- Use the handles to manually orient the partial denture so it is parallel to the platform with cameo surfaces facing the platform.
Your partial denture bases are now properly oriented and ready to be supported.
Partial denture bases are supported using two tools:
- The Patch tool automatically creates a field of supports. It is used to create supports for the anterior facial region.
- The Fence tool is used to manually place a thin wall of supports. Fences are placed along the lingual and buccal edges for lower dentures and along lingual edges on upper dentures. In some cases, fences are needed on bars or the posterior edges of upper dentures.
Support only intaglio surfaces. Leave cameo surfaces free from supports.
Before starting, optimize the interface for adding fences.
- Click Toggle Platform button in the lower tool bar or press the B key to hide the platform. This will enable better visibility during fence creation.
- Click Overhang Detection button (V key) to find areas that need support.
- Set the angle to 40-60 degrees.
- Click Supports in the dark gray bar.
- Under Part Position, select Above to create room between the platform and the part.
- Click the Manual tab and select Patch.
- Leave the Support Attributes at the default values.
Be sure to set Part Position to ABOVE before you begin adding supports.
Support large overhangs with Patch supports
Large overhangs are most easily supported with the Patch support tool. The example pictured is an upper partial denture.
- While in the Supports menu, click the Manual tab and select Patch
- Click in the large overhang at the anterior. A green patch will appear.
- Under Support Attributes click Primary Support Type and select Fence.
- In the Spacing box, space supports between 3-5 mm.
- Scroll down to the bottom of the Supports menu and turn Boundary Fence on.
- Adjust the Overhang slider until the highlighted overhang areas are covered by the green patch. Typically this iwll be between 40 and 60 degrees.
- Click Generate All.
Edges and tooth cups
Edges and tooth cups (islands) require manual fence supports:
- Click a series of points along the edge/tooth cup to define the fence.
- Click Esc key on keyboard to end a fence and begin another.
- Hold down the E key and click with the mouse to reposition points.
- Click Generate All to create the fence geometry. This may take a few minutes.
- Repeat as needed until all edges and tooth cups are supported.
Error: Support couldn't be added
Sometimes an error will occur when you try to generate a new fence.
If this happens, the points will turn pink and an error message will appear.
Try making multiple shorter fences or try adding the fence in a slightly different place.
Use the images below as a reference for a well supported partial denture. Click the images to zoom in.
Once full or partial dentures have been properly oriented and supported, they should be nested for printing.
- Select the Layout tool in the top menu bar.
- Under Auto Layout select Gen1 or Gen2.
- Gen1 is Carbon's standard tool
- Gen2 is Carbon's more recent algorithm that can improve nesting performance.
- Enter 5 mm in Padding. Values as low as 1-2 mm can also be used.
- For Gen1 auto layout, check Overlap bounding boxes. This gives the software maximum flexibility to fit the most possible parts on the build platform.
- For Gen2 auto layout, 3 options are available for part rotation: Default (0°, 90°, 180°, 270°), Limited (0°, 180°), Do not rotate (0°).
- Press the Auto Layout button to automatically nest the dentures.
If necessary, nesting can be changed manually:
- Click and drag parts to adjust their position.
- Modify Z rotation by using the Spin tool or by selecting the Orient button in the main menu bar and using the Z axis loop.
- Use the Part List tab as needed to more easily select models and focus on them.
The video below shows the process described above.
Click Print Controls or Shift + P in the top menu bar.
Slice Thickness should be Standard.
Reducing the slice thickness will increase print time and may reduce part quality and accuracy.
- Select the Project Analysis tab.
- Click Start Analysis and wait for the processing to complete.
- Note the required resin volume and print time.
- Click Add to Queue.
For questions about the resin properties, printing, washing or curing your parts, please contact the Desktop Health support team: