Revolutionising 3D printing with artificial intelligence

Dr George Freedman

Tue. 25. March 2025

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3D printing, commonly referred to as additive manufacturing (AM), is transforming many industries, including dental, biomedical, aerospace, construction and automotive manufacturing. This powerful technology mimics natural additive layering processes seen in nature, such as botanical growth and biological repair mechanisms. AM enables the production of intricate, high-precision components with reduced material waste and enhanced efficiency.

The integration of artificial intelligence (AI) into AM further amplifies its potential by optimising design, simulation and real-time operational control. AI-driven automation allows for improved process management, anomaly detection and predictive maintenance, ensuring consistent quality and functional reliability. Additionally, AI enhances customisation, allowing for tailored solutions in patient-specific medical applications and complex engineering designs.

However, successfully merging AI with AM requires a thorough understanding of the parameters of AI and the specific objectives of the AM process. When effectively combined, these technologies create a powerful synergy that drives innovation, efficiency and industry-wide transformation.

AI optimises product design by reducing complexity, improving material efficiency and accelerating production. Early integration of AI enhances performance optimisation, ensuring better outcomes. Unlike traditional 3D-printing quality control, which relies on post-production inspection, AI employs predictive analysis to detect and resolve issues before manufacturing begins, minimising waste and inefficiencies.

AI also enhances workflow efficiency by pre-analysing data, identifying potential bottlenecks and streamlining operations. By providing real-time insights, AI improves decision-making and ensures smoother production processes. Additionally, AI can manage both production and post-production planning, maximising efficiency and increasing overall yield.

“The International Academy for Dental 3D Printing will be holding a meeting at the Media Lounge of Dental Tribune International and OEMUS MEDIA in Hall 4.1 [on Wednesday at 17:00].”

Through intelligent automation, AI transforms AM, making it more precise, cost-effective and scalable. Its ability to predict, adapt and optimise contributes to higher-quality outputs and more efficient manufacturing workflows, benefiting various industries.

The financial aspects of integrating 3D printing and AI

The majority of dentists worldwide operate as private practitioners, running small businesses that are highly sensitive to operating costs, patient fee acceptance and market fluctuations. When an innovative procedure offers comparable or improved patient outcomes at a lower cost, it becomes highly attractive, especially if the initial investment and the effort and time required to learn to use the new technology are minimal. Historically, dental professionals have rapidly adopted advancements such as local anaesthetics for single-appointment multi-tooth treatments, high-speed handpieces for enhanced efficiency, ceramics for superior function and aesthetics, and alternative metal alloys to mitigate rising gold costs.

3D printing introduces a transformative shift in dental practice, seamlessly aligning with the ongoing digitisation and automation of the field. AM enables the production of high-quality, customised dental solutions at significantly lower costs, streamlining processes while enhancing precision. This shift presents practitioners with a compelling choice: maintain current prices to increase profitability or lower treatment costs to attract more patients, ultimately boosting revenue.

3D printing and AI for sustainable, streamlined workflows

Beyond financial advantages, 3D printing enhances treatment accessibility and customisation, improving patient satisfaction and clinical outcomes. Digital workflows reduce material waste and turnaround times, making procedures more efficient. The ability to produce in-house restorations, aligners and surgical guides reduces reliance on third-party laboratories, giving dentists greater control over quality and delivery times. As the dental industry embraces 3D printing, practitioners can leverage these benefits to remain competitive, expand their services and optimise patient care in an increasingly technology-driven healthcare landscape.

While the dental profession has primarily focused on the 3D printing of laboratory products and, more recently, dental restorations, the potential applications extend far beyond these initial uses.

Artificial intelligence can help to manage both production and post-production planning, maximising efficiency and increasing overall yield. (Image: Juan1023/Shutterstock)

AM supports a wide variety of dental substrate materials, including resins and resin composites, which are already well established. Ceramics and metals, though more complex, are beginning to make a significant clinical impact. The use of polymer–metal blends allows for high-precision manufacturing, improved longevity and biocompatibility for implants, artificial joints and other high-stress applications. The complex processes required for these applications fall well within the scope of AI. The emerging field of biomaterials, which includes hydrogels and bioinks for bioprinting tissue scaffolds and medical products, is an area where AM and AI must work in tandem.

Since AM is a relatively new field, quality assurance is critical in the absence of long-term clinical data. AI-powered computer vision automates defect detection and enhances quality control during printing. Reinforcement learning refines multifaceted workflows by dynamically adjusting parameters to enhance efficiency and accuracy. AI also minimises production time and material waste by analysing data and recommending refinements before or during the process. Topology optimisation refines lattice structures and orientation for strength and weight efficiency, and finite element analysis assesses material properties and structural integrity, accurately predicting the success and longevity of the restoration, thereby reducing the likelihood of clinical failure.

Looking to the future

Continued advancement in AM technology and materials will be driven by AI innovations and predictive assessments. At the same time, AI will evolve alongside AM to maximise its potential in revolutionising production processes for patient care.

To ensure successful integration, open and ongoing communication is crucial among dentists, laboratory technicians, software and hardware developers, industry partners and media professionals. Keeping all stakeholders informed fosters collaboration and drives innovation in dental AM and AI applications. At the Internationla Dental Show 2025, the International Academy for Dental 3D Printing will be holding a meeting at the Media Lounge of Dental Tribune International and OEMUS MEDIA in Hall 4.1, together with members of the Dental AI Association to further this dialogue. The meeting will be held on Wednesday at 17:00.