Workflow Guide

3D Printing Surgical Guide

With the everyday increases in dental implant demand, the standard dental care requires a guided surgery for implant placement to have better predictability and accuracy while reducing the risks to ultimately provide a better patient experience with more successful procedures. Today, it is very easy and accessible to digitally plan implant placement by using a CT scan and intraoral scan of the jaws, designing a Surgical Guide in a dental implant CAD software, and finally fabricating the surgical guide by using a biocompatible resin in a SprintRay 3D printer.

Here we show and walk you through every step involved in the workflow of fabricating a Surgical Guide in your office, from impression taking to completing the appliance.

1. Digital Impression

What you need: Intraoral or desktop 3D scanner, and CBCT data

2. Digital Design
Select surgical guide

What you need: Designing is done on an Implant Planning software, which can be done in house or through a service provider.

3. Digital Fabrication
What you need: SprintRay Pro 3D printer, Pro Wash/DryTM, ProCure, SprintRay Surgical Guide 3, RayWare software, IPA, flush cutter, lab pearl-shape carbide bur, Scotch BriteTM/FuzziesTM fine polishing wheel.
4. Assembly/Sterilization

What you need: Surgical Guide Sleeve, Muslin, Pumice, Nitrile gloves, Protective eyewear.


Digital Impression

The first step in this workflow is to obtain CBCT data and digitally record a patient’s dentition information by a digital impression for being able to design the Surgical Guide in CAD software. We can either take a direct or indirect digital impressions.

Time required: 5-10 min

1.1. Using Intraoral Scanner
Use an intraoral scanner to take direct digital impressions, then export STL files. Common compatible scanners include, but are not limited to: Primescan (DentsplySirona), iTero (Align Tech), Trios (3Shape), Omnicam (DentsplySirona), Emerald (Planmeca), Medit (Medit), CS3700 (Carestream).


1.2. Using Desktop Scanner
Indirect digital impressions are done by using a desktop scanner to convert a VPS impression or a model into a digital impression. Once the maxillary, mandibular, and bite scan files (digital impressions) are ready, export and save them in the highest resolution (if you have the option of choosing resolution) on your computer in STL format.


Pro Tips

  • Primescan does not allow exporting bite-scan as a separate file. By default, Primescan users can only export 2 files: upper and lower. In case you need to export bite-scan as a separate file, you need to follow the steps from this link: Link to “How to export separate bite-scan file from Primescan
  • To avoid rescanning and delays to the workflow, make sure all critical and required areas are scanned and captured. This will mitigate any delays in the treatment and discomfort to the patient. Here are some examples of problematic scans:
Occlusion is unclear and scan has bubbles.
Scan has scraps.
Scan is coincident and contains distortion.
Scan is incomplete, missing images.

Surgical Guide Design

Designing the Surgical Guide is the second step in this workflow. Designing can be done either by using an outside provider, or it may be done in-house by the dentist.

Time required, if done in-office: 12-20 min.

2.1. Out of Office Surgical Guide Design
SprintRay Cloud Design helps and provides accurate Implant Planning and high-quality Surgical Guide Design, where you can upload patient's intraoral scan files, CBCT images, and your prescription. Click here for more information on SprintRay Cloud Design services: SprintRay Cloud Design. This process is done in 2 steps: first, you receive a link to a set of validated information regarding the implant planning guide design (such as a video summary, STL files, quality control images, and PDF files). Once the implant planning is approved, you will be sent the actual design file for the Surgical Guide. Once you receive the STL file of the designed Surgical Guide from SprintRay Cloud Design, you may go directly to step 3 (Fabricating Surgical Guide)

Select surgical guide

2.2. In-Office Designing Surgical Guide Design
This is done in a Splint CAD software. SprintRay Software allows you to choose a splint software that best meets your clinical needs. Below is the list showing our recommended options, however, our software accepts any design file formatted in STL, which means you can use whichever software you are most comfortable with: 3Shape Splint Studio, Exocad, Magics, D3splint. Once the scans are imported to the design software:


2.2.1. Proper Software Settings Required
Follow the instructions for SprintRay Surgical Guide material and choose/provide proper settings in the software. Continue to complete the implant planning followed by designing a Surgical Guide.

2.2.2. Export Designs as STL 
Once Surgical Guide is designed, the appliance should be exported and saved in STL format.


Surgical Guide Fabrication

Fabricating the Surgical Guide is the third step in this workflow. Once the design of the appliance is ready, you may start printing it using RayWare software and a SprintRay Pro printer. Below, we will show you the steps involved in fabricating the Surgical Guide.
If you use SprintRay Cloud Design services to design the Surgical Guide, you may use the direct print option. Click on the “Print” button and send the design directly to the printer. In this case, you may jump to step 3.5, otherwise, continue with step 3.1. Click here to learn more about direct print option and workflow on SprintRay Cloud Design services: SprintRay Cloud Design


Assembly and Sterilization

The last step in this workflow prepares the printed Surgical Guide for surgery. At this step, we want to make sure the surgical guide is polished, the sleeve is assembled properly on Surgical Guide, and fully sterilized. Below, we will show you the steps involved in Polishing, Assembly, and Sterilization.

Time required: 10 minutes


4.1. Polishing
Use a muslin polishing wheel and pumice, with a firm and consistent pressure, to reach all the appliance areas. Make sure the wheel and pumice are damp enough and the pumice is flowable.

Surgical Guide brush

4.2. Cleaning and disinfecting the Surgical Guide
Use dish soap and a soft toothbrush to clean the appliance before assembly.


4.3. Assembling the Surgical Guide sleeve
The Surgical Guide sleeve helps avoid any damage to the surgical guide. A Surgical Guide sleeve is fitted into the corresponding surgical guide drill hole. Make sure to select a proper and compatible sleeve at the time of treatment submission.


4.4. Sterilization
The Surgical Guide is then autoclaved at 134o for 5 minutes. You may use a sterilization pouch for sterilization. If disinfection is required, use non-chemical products. If this is not possible, IPA solution is recommended for 5 minutes to disinfect.

Pro Tips

  • Use protective eyewear at all times to avoid eye injuries.
  • Make sure the Surgical Guide is completely dried after sterilization.
  • Do not expose the Surgical Guide to excess heat or time during sterilization.
  • If soaked in IPA to disinfect, do not exceed more than 10 minutes.

For further information or any questions, please contact our Customer Support team from Monday through Friday, 7AM - 5PM PST at (800) 914 8004, or visit