Automated 3D Printing Is a Dream Come True for Laboratory With Patient-First Approach

HeyGears’ UltraCraft 3D printers, HiVE automation add-on, and Dream Factory transform workflow

Josh Gall and Ha Van had a vision when they joined forces at BioTec Dental Laboratory in Tustin, California. Having worked together for several years at a larger laboratory, they wanted BioTec to be different. "We made a commitment to a patient-first, people-focused approach," says Gall, who is Head of Implants alongside Van, the General Manager. "Our main concern has always been the patient. We want to help dentists improve patients' overall health and well-being in any way we can. It is not about the tasks we perform; it is ingrained in who we are. We are not just a dental laboratory. We are a group of passionate individuals who care about patients and helping dentists take care of them."

As digital technology has evolved, so has BioTec's ability to fulfill that commitment. "All of the digital concepts and innovations over the years have made that job easier," Gall says. The laboratory's digital journey began in 2017 with low-priced 3D printers for models, basic software, and what Gall refers to as "ancient" milling machines. "As the size of our laboratory, our education, and our experience all increased," he says, "the digital options improved across the board in the industry. Rapid technological change and evolution in this field has allowed us to stay up to date and adapt to the ever-changing environment."

The most significant development, Gall says, was when BioTec partnered with HeyGears on 3D printing solutions. BioTec uses the HeyGears UltraCraft A2D, A2D Ortho, A2D 4K + HiVE, and A3D printers. "Their commitment to evolving the technology with us has been truly invaluable, providing us with the support that we knew we needed—and even showing us some things we did not even know we needed along this journey," Gall says.

The relationship began because BioTec was experiencing an uptick in customers and needed to print more models. "The main objective at the time was truly to keep afloat with our model production," Gall says. Quickly, however, BioTec discovered HeyGears' other solutions. "Our customer base kept growing, and HeyGears really came along at the right time with a way to bridge the gap from where we were to where we wanted to be, while ensuring that we remained on the forefront of innovation," Gall says.

Gall says the UltraCraft A2D 4K with the High-Volume Enabler (HiVE) Module has made the biggest impact on BioTec. The UltraCraft A2D 4K is designed for mass production with extremely high precision, and the HiVE provides higher-volume throughput with automatic part removal in less than 3 minutes per platform; automated material refill; and 24-hour nonstop production throughout the entire workflow. "It has allowed us to almost double our workload with less manpower," he says. "We have not felt much strain at all." Indeed, staffing was a significant challenge for BioTec initially with such rapid expansion, but HeyGears' solutions made scaling easy. "Fortunately, the HiVE somewhat started to manage itself," Gall says. "We were able to empower our people with HeyGears' constant support. They really helped us shape that management and create the workflow that we have today for quality control and overall printing operations." In addition to increasing their throughput on existing offerings, BioTec has been able to add new product lines with its expanded 3D printing capabilities. "We have been able to offer printed night guards, soft tissue, and hybrid ceramics—products that are gaining in popularity among our customers," Gall says.

Of course, automation is only helpful if the hardware in question produces high-quality work. HeyGears printers have met BioTec's high standards. "The quality of our printed models and restorations really hinges on the resolution quality and the accuracy of the models," Gall says. "HeyGears' high-quality hardware and software have not only ensured that our operations run smoothly, but they have allowed us to maintain the level of excellence that we have prepared our clients to expect from us." The HeyGears printers allow users to select from multiple options for resolution and speed; BioTec has settled on 50-μm resolution. "That level of precision dramatically reduced our remakes and adjustments," Gall says.

When BioTec recently moved into a new facility, the laboratory built a HeyGears Dream Factory—an innovative service whereby HeyGears designers help create a dedicated 3D printing workspace to streamline production. "The Dream Factory was a game-changer," Gall says. "Our HeyGears representative's personal touch helped make this space something truly impactful."

Overall, Heygears' products and support have helped BioTec manifest the vision that Gall and Van laid out when they first partnered. "Collaborating with HeyGears has been a significant stride toward embracing and advancing our digitally driven future, as well as the digitally driven future of the dental industry," Gall says. "It has helped us stay ahead of the curve. It has redefined and reshaped how we approach our care for our customers. As we continue streamlining our workflow even further, we look forward to increased quality, shortened turnaround times, and overall greater patient satisfaction."

UltraPrint-Dental Cast UV 3.0

HeyGears Cast UV 3.0 is designed for highprecision dental casts. Printing results are precise and without any misshapes. The residue-free burnout process allows easy production of removable partial dentures (RPDs), post and core, and crowns.

For more information, contact:
HeyGears
heygears.com
318-353-4295