Why Polymer SLS is Shaping the Future of Dental Appliance Production

June 02, 2025 | Reading time: 5 min

Over the past decade, we’ve seen digital workflows in dentistry evolve from early-stage exploration to fully integrated production ecosystems. And throughout that transformation, one technology has quietly but consistently proven its value: polymer-based Selective Laser Sintering (SLS).

At EOS, we’ve worked closely with dental labs, orthodontic manufacturers, and healthcare innovators for over 10 years — supporting them in building robust, scalable workflows based on SLS. Today, many of the world’s leading dental and orthodontic providers are running multi-system SLS production setups using EOS equipment — producing tens of thousands of high-precision appliances annually.

In this article, I want to share what makes polymer SLS such a reliable and future-ready technology for dental applications — and why it’s become a trusted choice for those looking to scale without compromising quality.

Key Advantages of Polymer SLS in Dental Appliances Production

• Strength Without Bulk: SLS nylon offers a rare combination of rigidity and flexibility, ideal for devices like occlusal splints, bite guards, and orthodontic appliances.
• True Geometric Freedom: Prints without support structures, enabling complex geometries and reducing post-processing.
• Reliable Accuracy and Reproducibility: EOS systems offer process stability and consistent dimensional accuracy.
• Scalable for High-Volume, Customized Production: Efficient batch production for personalized appliances.

A Proven Track Record in Dental & Orthodontic Production

EOS has been supporting dental manufacturers for over a decade, and many customers now run multi-machine SLS production lines. This includes manufacturing functional splints, trays, bite devices, orthodontic models, and temporary appliances.

Comparing the Alternatives

• Acrylic (PMMA): Moderate durability, technician-dependent accuracy, labor-intensive post-processing.
• SLA Resin: Moderate durability, high accuracy but susceptible to warping, requires washing and curing.
• Polymer SLS (PA 2200): High durability, consistently high accuracy, minimal finishing, scalable batch production.

Looking Ahead

As digital dentistry scales, the need for repeatable, high-throughput production grows. Polymer SLS offers a mature, field-tested solution that meets both current and future demands. EOS continues to support the industry's shift from experimental 3D printing to full-scale production.

Want to Explore SLS for Your Workflow?

Whether you’re exploring your first 3D printer or ready to expand your production line, we’re happy to share what’s worked for other customers, discuss material options, and help evaluate where SLS might fit in your workflow.