Redefining Dental Medicine: Orthos’ Digital Shift with Additive Manufacturing

Traditional treatments for sleep apnea, such as Continuous Positive Airway Pressure (CPAP) therapy, have significant drawbacks. Many patients find the masks to be loud, uncomfortable, and restrictive. This has led to a staggering 50% of patients abandoning treatment altogether, even if they knew there was no alternative.

Furthermore, the conventional manufacturing of Mandibular Advancement Splints (MAS), a viable alternative to CPAP, was a labor-intensive process. It required multiple materials and was prone to inconsistencies, often resulting in splints that were difficult to wear and could cause allergic reactions due to uncured plastics.

Orthos recognized this as a critical gap in the market. The lab needed a manufacturing method that could not only produce a high-quality, comfortable device but could also be integrated seamlessly into a modern digital workflow, ensuring consistency and precision for every patient. Beyond patient comfort, Orthos targeted lab-side bottlenecks: variable fit and rework from multi-material interfaces, bulkier wall sections from manual processes, and chair-time tied to remakes — issues a single-material digital approach could systematically reduce.

The move to EOS technology has had a transformative effect on Orthos' business and the patient experience. The digital process eliminates the mess and labor-intensity of traditional methods, creating a cleaner, more efficient operation. In day-to-day production, technician touch time per splint now tracks with published digital-workflow benchmarks — down roughly from ~163 minutes to ~48 minutes — freeing capacity without adding headcount. With the digital data stored, a lost or damaged appliance can be remanufactured with ease and consistency, unlike the manual process which required starting over from scratch.

This has also significantly reduced clinical time spent on breakage reviews and repairs, a major pain point with old appliances. A single-material PA12 design removes weak joints and adhesive interfaces, enabling thin, comfortable rims that patients actually tolerate. Patient comfort and compliance have soared, with dentists reporting high patient satisfaction and a dramatic reduction in breakage complaints. The effectiveness of the new devices has also been proven in the field; Orthos' Lunasol products, for example, have been tested by over 7,500 dentists in the DACH region.

"Only EOS technology can provide the combination of pure white, biocompatible, and completely safe materials and processes that can be easily adapted and reproduced. It uses a thermoforming process that is well accepted in the dental and medical fields. Unlike chemical bonding methods, it simply involves melting the powder material layer by layer to produce the oral appliances. This makes it easy for our customers to understand and trust," Dörr explains.

The partnership with EOS has allowed Orthos to produce a unique, single-material product that addresses the core issues of traditional sleep apnea treatments. The process offers a level of process security and consistent results that were previously unattainable, while also leveraging a fully recyclable powder. By combining a digital workflow with advanced additive manufacturing, Orthos is not only building better dental appliances but also building a better quality of life for its patients. The company has successfully transitioned from a traditional dental lab to a manufacturing leader, showcasing the power of - to solve complex medical challenges and redefine an entire industry.