Dental technology is changing fast. One of the biggest shifts happening right now involves how dental models are made. Printed models are quickly replacing traditional stone models in labs and dental practices across the country — and for good reason.
For dentists in Phoenix, Scottsdale, Mesa, and Chandler, this shift matters. It affects turnaround times, accuracy, and ultimately, patient outcomes. Therefore, it is worth understanding what each model type offers and where the differences truly lie.
At Dentek Digital, we have been at the forefront of digital dentistry for years. We help dental practices across the Greater Phoenix area make smart decisions about their workflows. In this post, we break down the key differences between printed models and traditional stone models so you can choose confidently.
What Are Traditional Stone Models?
Traditional stone models have been the standard in dentistry for decades. They are created by pouring a gypsum-based material — commonly called dental stone — into a physical impression taken from the patient’s mouth.
Once the material sets, the result is a hard, physical replica of the patient’s dentition. These models are then used to fabricate restorations, plan treatments, and communicate between the dentist and the lab.
How Stone Models Are Made
First, the dentist takes a physical impression using a tray and impression material. Next, that impression is sent to the dental lab. Then, lab technicians pour liquid dental stone into the impression and allow it to harden.
This process is time-tested. However, it has several well-known limitations that modern technology is now solving.
Common Challenges With Stone Models
- Impression errors: Bubbles, tears, or distortions in the impression affect the final model.
- Dimensional changes: Stone can shift slightly as it sets, which affects fit.
- Fragility: Stone models can chip or break during handling and shipping.
- Storage demands: Physical models require significant space over time.
- Slower turnaround: Shipping physical impressions adds days to the process.
These challenges have driven many dental practices in Gilbert, Tempe, and across the Valley to explore digital alternatives.
What Are Printed Models?
Printed models are three-dimensional replicas of a patient’s dentition created using a 3D printer. Instead of a physical impression, the process begins with a digital scan — either from an intraoral scanner at the dental office or from a scan of a physical impression at the lab.
That digital file is then processed using specialized software and sent to a high-precision 3D printer. The result is a highly accurate physical model made from dental-grade resin.
How the Digital Workflow Works
First, the dentist captures a digital impression using an intraoral scanner. Next, that file is sent digitally to the lab. Then, our team at Dentek Digital processes the scan, designs the restoration, and prints the model — all within a streamlined digital workflow.
Because of this approach, the entire process is faster, cleaner, and far more consistent than traditional stone model fabrication.
Materials Used in 3D Printed Dental Models
Modern dental 3D printers use photopolymer resins that are biocompatible and purpose-built for dental use. These materials cure under UV light to create strong, dimensionally stable models. Additionally, different resin formulations are available for different clinical needs — from model printing to surgical guides and splints.
Printed Models vs Stone Models: A Side-by-Side Comparison
Understanding the differences helps dental practices make informed decisions. Moreover, it helps you set realistic expectations for your patients and your lab workflow.
Accuracy and Fit
Both model types can achieve excellent accuracy when handled correctly. However, printed models have a consistent advantage. Digital scans capture the dentition with precision that is difficult to match with physical impressions.
Stone models are vulnerable to impression errors, pouring technique, and material variability. Printed models, on the other hand, start from a clean digital file. As a result, the margin for human error is significantly reduced.
At Dentek Digital, we use industry-leading 3D printers calibrated for tight tolerances. This allows us to produce printed models that support highly accurate dental restoration fabrication every time.
Turnaround Time
Traditional stone models require physical impressions to be shipped to the lab. This alone can add two or more days to the process. Furthermore, the pouring, setting, and trimming of stone models takes additional time in the lab.
Printed models eliminate shipping delays when digital scans are submitted. The lab receives the file instantly and can begin processing the same day. Therefore, turnaround times are often meaningfully faster with digital workflows.
Durability and Handling
Stone models are relatively fragile. They can chip or break during trimming, handling, or shipping. Once broken, a stone model is often unusable.
Printed models made from quality dental resins are more resistant to chipping and breakage. Additionally, the digital file is always saved, so reprinting a model is straightforward if needed. This is a major operational advantage for busy labs and practices.
Storage and Record-Keeping
Stone models require physical storage space. Over years of practice, this can mean shelves, drawers, or entire rooms dedicated to model storage. Managing and retrieving the right model is also time-consuming.
Printed models solve this problem elegantly. The digital file lives in the cloud or on a secure server. Therefore, storage is virtually unlimited and retrieval is instant. For practices in fast-growing communities like Gilbert or Chandler, this scalability is especially valuable.
Environmental Considerations
Traditional stone models generate significant material waste. Impression materials, excess stone, and broken models all end up as waste. On the other hand, 3D printing uses only the resin needed for the model, reducing overall material consumption.
Furthermore, eliminating the need to ship physical impressions reduces the carbon footprint of the lab workflow.
When Stone Models Still Make Sense
It is important to be balanced here. Traditional stone models are not obsolete. In certain clinical situations, they remain a practical choice.
For example, some dentists in the Phoenix area may not yet have access to an intraoral scanner. In these cases, physical impressions are still necessary. Additionally, some complex full-arch cases or specific orthodontic workflows may benefit from physical study models for hands-on evaluation.
However, even in these situations, physical impressions can be scanned at the lab and converted into digital files. From there, printed models can still be produced. So the transition to digital does not have to happen all at once.
If you are unsure which approach fits your current setup, contact Dentek Digital and our team will walk you through your options.
How Dentek Digital Uses Printed Models
At Dentek Digital, printed models are a core part of our daily workflow. We use them across a wide range of restorative and prosthetic cases — from single-unit crowns to full-arch implant cases.
Our lab is equipped with high-precision 3D printers that produce models with tight dimensional accuracy. We calibrate our equipment regularly to maintain consistency. As a result, the restorations we fabricate on printed models fit reliably when seated in the patient’s mouth.
Printed Models for Fixed Restorations
For crowns, bridges, and veneers, accuracy is everything. Printed models allow our technicians to verify margins, contacts, and occlusion before the final restoration is delivered. This step improves outcomes and reduces remakes.
Printed Models for Implant Cases
Implant restorations demand precise model articulation. Printed models support accurate analog or digital implant placement verification. Additionally, they integrate seamlessly with our digital implant planning services — a major advantage for complex implant cases.
Printed Models for Splints and Nightguards
We also use printed models for fabricating splints and nightguards. The precision of the printed model ensures a well-fitting appliance that your patients will actually wear. This is a frequently cited improvement over stone-model-based appliances.
Frequently Asked Questions About Printed Models
Are printed models as accurate as stone models?
Yes — and in many cases, more so. Printed models start from a precise digital scan, which eliminates common impression errors. When calibrated correctly, 3D printers produce models with excellent dimensional accuracy.
Do I need an intraoral scanner to use printed models?
No. If you take physical impressions, your lab can scan them and produce printed models from the resulting digital file. This allows you to benefit from printed model accuracy even without an intraoral scanner in your office.
How durable are printed dental models?
Modern dental resins are durable and resistant to chipping during normal lab handling. They hold up well through crown and bridge seating, appliance fabrication, and articulation workflows. Moreover, the digital file can always be used to reprint if needed.
Will printed models work for all case types?
Printed models support a wide range of case types, including fixed restorations, removables, implant prosthetics, and occlusal appliances. In some specialized workflows, your lab may recommend a different approach — but most everyday cases are well-suited for printed models.
How do I get started with printed models through Dentek Digital?
It is simple. You can submit a digital scan directly or send us a physical impression to scan at our lab. Our team handles the rest. Explore your options and reach out to us to discuss your specific case needs.
Making the Switch: Practical Tips for Phoenix-Area Dentists
Transitioning from stone models to printed models does not have to be overwhelming. Here are a few practical steps to help you get started.
- Start with one case type: Try printed models for a single restoration type first, such as single-unit crowns, before expanding to full-arch cases.
- Communicate with your lab: Let your lab know you want to explore printed models so they can guide your scan submission process.
- Evaluate scan quality: If you use an intraoral scanner, ensure your scans capture full arch coverage and clear margins.
- Review fit outcomes: Track how restorations seat compared to stone-model cases. Most dentists report equal or improved fit with printed models.
- Ask questions: A good lab partner — like Dentek Digital — will walk you through the workflow and troubleshoot any issues.
Dental practices in Scottsdale, Mesa, Tempe, and throughout the Phoenix metro area are already making this transition. The workflow is proven, and the benefits are real.
Partner With Dentek Digital for Your Printed Model Needs
Dentek Digital is one of the most experienced digital dental labs in the country. We were among the earliest adopters of the CAD/CAM digital workflow, and we continue to lead in precision, technology, and service.
Whether you are already scanning digitally or still working with physical impressions, we are ready to support your transition to printed models. Our team brings deep expertise in digital workflows, and we partner closely with dentists and practices across Greater Phoenix to deliver consistent, high-quality results.
Send us a case and experience the Dentek Digital difference for yourself. We look forward to supporting your practice and your patients.