Carbon FP3D (Pre-Release Access)
Caution: Product for lab evaluation, not for clinical use
FP3D (manufactured by Keystone Industries®) is a two-part resin developed for producing flexible removable partial dentures. Engineered using Carbon’s proprietary dual-cure chemistry, FP3D sets a new industry standard by delivering a unique combination of durability, stain resistance, dimensional accuracy, and flexibility.
Beyond its material strengths, FP3D easily integrates into Carbon’s digital denture workflow, assisting in reliable, economical, and quick production.
Carbon's two-part resins differ from the one-part resins used throughout the dental industry in a few important ways.
- The two components (Part A & Part B) of FP3D are stored in separate chambers in a cartridge, similar to an epoxy you may purchase at a hardware store.
- The components are combined at the time of use by using a battery-powered dispenser and a disposable mixing tip.
- Once combined, FP3D has an 8 hour life span called a pot life. After the resin has aged beyond its pot life, it is not suitable for printing and should be disposed.
- Some salt will stick to parts during baking and must be washed off afterwards.
Carbon's two-part resins require equipment that will be new to most dental labs.
A powered dispenser is required to push the resin components out of the cartridge and through a disposable mixing tip.
Go to Cartridge Dispensing for more information.
Yamato Convection Oven
Like all of Carbon's two-part resins, FP3D partial dentures require thermal curing in a convection oven to attain their ultimate mechanical properties.
See Yamato Convection Oven for more information including programming and operating instructions.
The Yamato Convection Oven has ventilation and electrical infrastructure requirements. See the facility requirement checklist for your printer for specific information.
Salt baking requires a variety of supplies and equipment including
- Powder grain salt - supports parts during thermal curing
- Baking pans - oven-safe pans that hold the salt and parts
- Salt strainer - strains out clumps of salt or other large particulates that can negatively affect part accuracy
- Foil - covers the pan and contains salt during baking
See Salt Baking for more information.
The above items are all available on the Accessories & Supplies page.
- Partial denture thickness should be 1 - 3 mm.
- Incorporate splay bars to prevent splaying of parts during curing.
- Splay bars should be equivalent to the median thickness of the partial denture.
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.
In the Resin dropdown, select FP3D.
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 dentures on the platform.
For detailed information about orienting parts, read Orient.
Orient partials vertically with the posterior at the platform (anterior rotated away from the platform).
Upper Partial
Lower Partial
See Supports for detailed information.
Select the Supports tab in the top bar or press Shift + S.
In the bottom bar, toggle Overhang Detection on and set the angle to 40 degrees.
Also in the bottom bar, set Toggle Platform to off.
Set Part Position to Above.
Support posterior edges with fences.
- Avoid adding supports to intaglio surfaces.
- Add fences to horizontal splay bars.
- Do not add fences to areas higher than about 30 mm above the platform. These areas require bar supports.
Add bar supports.
- Support overhangs that are more than 30 mm above the platform.
- Add bars to any overhangs where fences did not generate.
- Add bars to reinforce fences that support clasps or other delicate features.
For best accuracy, do not under-support clasps.
Set Slice Thickness to Standard (100 µm).
Reducing the slice thickness by choosing the Fine (50 µm) or Super-fine (25 µm) settings will increase print time and may reduce part quality and accuracy.
Dispensing the two-part resin FP3D is very different from pouring out one-part resins. In particular, the 8 hour pot life is a new variable that needs to be kept in mind.
Read Cartridge Dispensing for detailed information about setup and operation of the Cox Dual-Drive Dispenser.
Set up the Cox Dual Drive Dispenser.
- Check the battery.
- Install E:F ratio plates.
- Set speed to 3.
Install the orange mixing tip on the cartridge.
Slide the cartridge into the dispenser.
Place the shroud over the mixing tip.
Dispense and discard approximately 10 mL of resin.
Dispense the required resin into the cassette.
Install the cassette with the newly dispensed resin in the printer.
Start printing.
When printing is complete, remove the platform to begin post processing.
See Printing for more information.
The washing process for FP3D is similar to washing most one-part dental resins.
FP3D has a total maximum solvent exposure time of 5 minutes.
Remove the printed parts from the platform.
Remove the supports from the parts.
Supports are easily removed manually.
Using a blue shop towel can help keep sticky resin off of your gloves.
First wash.
- Add parts to washing container of fresh IPA.
- Place container on orbital shaker and wash parts for 2 minutes at 140 RPM.
Detailed cleaning.
- Remove parts from IPA.
- Wet a toothbrush with IPA and remove any liquid resin from tooth pockets, intaglio surfaces or anywhere that resin can be trapped.
Second wash.
- Place parts in container of fresh IPA.
- Place container on orbital shaker and wash parts for another 2 minutes at 140 RPM.
Dry the parts.
- Place parts on clean surface to dry.
- Alternately, use compressed air to dry parts.
FP3D parts must be thermally cured (baked) in a Yamato convection oven.
Program the Yamato convection oven.
Before parts can be cured, the oven must be programmed with the appropriate temperatures and timings for curing FP3D.
Add salt to the baking tray.
- Use a sifter to add salt to a 75 mm (3 inch) deep baking tray.
- Add approximately 25 mm (1 inch) of salt.
- Shake and/or tap the tray to make the surface of the salt relatively flat.
Replace salt after 10 curing cycles to ensure part cleanliness.
Place the parts in salt.
Parts must be completely dry before placing in salt.
- Place each part intaglio side up in the salt.
- Gently nestle each part into the salt so that all down-facing surfaces are supported by the salt.
Cover the parts with salt.
- Using the sifter, add about 25 mm (1 inch) of salt on top of the parts.
- To enable even heat distribution during baking, the parts should have the same amount of salt above and below them.
- Shake and/or tap the tray to make the surface of the salt relatively flat.
Cover tray with aluminum foil.
- Cover tray with aluminum foil.
- If necessary, write identifying information on a metal tent sign and place it on top of the foil.
Bake the parts.
- Place covered tray in the oven.
- Start the FP3D bake program:
- 15 minute ramp to 120° C
- Hold at 120° C for 10 hours.
Remove the parts from the oven.
The tray and interior of the oven will be hot. Use caution when removing items from the oven.
- Wearing heat-resistant gloves, remove the pan from the oven and allow it to cool (~27° C).
- Alternately, parts may be allowed to cool inside the oven.
FP3D parts will change color after baking.
Rinse parts with warm water to remove excess salt from the surface.
- A toothbrush can help remove salt residue, but it is not required.
Dry parts.
- Place parts on a clean surface to dry.
- Alternately, use compressed air to dry parts.
FP3D partial dentures require a final UV cure cycle. See the protocol sheet above for more info.
Bond the teeth to the partial denture.
- Follow the tooth bonding instructions for your tooth material of choice.
FP3D partial dentures require a final UV cure cycle. If the tooth bonding instructions do not include a final UV cure, refer to the FP3D protocol sheet above for final UV curing instructions.
Finishing the partial denture.
Condition the finished partial denture.
Finished flexible partial dentures should be conditioned in a room temperature, aqueous solution (water or cleaning solution) overnight for a minimum of 12 hours before use.
Your partial denture is now complete!
