Removable Partial Denture Fabrication
SprintRay Apex Flex & Apex Teeth — Lab Manufacturing Procedure
| Owner | Lab Technician (process owner) |
|---|
| Applies to | Smile Avenue Family Dentistry in-house lab |
|---|
| Start | Case received in Medit Lab |
|---|
| End | Prosthetic bagged and logged in SEAZONA for outbound delivery |
|---|
| Related | Station Job Aid SOP-LAB-030-JA |
|---|
1. Purpose
This procedure standardizes in-house manufacturing of SprintRay flexible removable partial dentures (Apex Flex Partial Base with Apex Teeth) so every case meets the same quality, safety, and traceability standard before leaving the lab.
2. Scope
- In scope: Medit Lab intake → scan QC → Heygears portal design → RayWare / Pro 2 Duo Kit print → ProWash S → assemble & NanoCure → finish & polish → lab clean → bag & SEAZONA outbound log.
- Out of scope: Chairside scanning technique; clinical try-in and patient delivery; chairside chemical disinfection; nightguards; cast-metal frameworks; non-SprintRay printers.
3. Roles
| Role | Responsibility |
|---|
| Clinical Assistant / Office | Sends case via Medit Lab; receives bagged prosthetic from lab |
| Lab Technician | Scan QC, Heygears portal submit/export/approve, manufacture, finish, bag, SEAZONA log |
| Trainer / Lead Lab Technician | Competency observation and sign-off |
| Doctor | Clinical indication, try-in, and remake authorization (outside manufacturing steps) |
4. Practice Configuration
| # | Item | Smile Avenue setting |
|---|
| 1 | Printer (Flex base) | Pro 2 |
| 2 | Cure unit | NanoCure — cycle Apex Flex Denture |
| 3 | Case intake | Medit Lab |
| 4 | Design | Heygears portal (Heygears designs; Lab Technician imports, exports, approves) |
| 5 | Duo Kit | Yes |
| 6 | Wash | ProWash S |
| 7 | Apex Flex shades | Stock Standard Pink and Light Pink; select per prescription |
| 8 | Apex Teeth default | A2 (other shades per prescription) |
| 9 | Lab clean before bag | Soap, toothbrush, and warm water (and/or steamer), then dry. This is cleaning — not chemical disinfection. |
| 10 | Design approval before print | Lab Technician |
| 11 | Case log | SEAZONA |
5. Safety
- Treat uncured Apex Flex and Apex Teeth as sensitizers. Work in a well-ventilated area.
- Wear nitrile gloves, protective eyewear, lab coat or gown, and face protection when handling uncured resin, IPA, or grinding/polishing.
- Do not place incompletely cured resin in the mouth. Do not bag an under-cured appliance.
- Skin contact: wash with soap and water. Persistent irritation: stop work and follow the SDS.
- Do not substitute non-validated printers, washers, cure units, or bonding resins for Apex Flex bases.
- Cure liquid waste resin fully before disposal. Follow hazardous-waste rules until cured.
6. Materials & Equipment
Resins
- SprintRay Apex Flex (Standard Pink, Light Pink)
- SprintRay Apex Teeth (Bleach, A1, A2, B1 — default A2 unless prescribed otherwise)
- IPA ≥91%
- Apex Flex resin for tooth-to-base bonding
Equipment stack
| Step | System |
|---|
| Intake | Medit Lab |
| Design | Heygears portal |
| Nest / print | RayWare → Pro 2 + Duo Kit |
| Wash | ProWash S |
| Cure | NanoCure — Apex Flex Denture |
| Case log | SEAZONA |
Design QC targets (review Heygears design)
| Area | Minimum |
|---|
| Palatal / lingual wall | ≥ 1.0 mm |
| Facial / buccal wall | ≥ 1.0 mm |
| Implant overdenture area | ≥ 1.5 mm |
| Apex Teeth thickness | ≥ 0.5 mm |
| Clasp thickness (target) | ≥ 1.2 mm |
Export separate base and teeth STL files for Duo Kit printing.
Polish kit (SprintRay Master Workflow Guide — Partial Dentures)
| Step | Tools / media |
|---|
| Smooth supports | Lab handpiece; abrasive wheel or carbide bur (low RPM); Scotch-Brite / Fuzzies as needed |
| Resilience polish | Dental lathe; black bristle wheel B27/B29; Resilience polish (wet, not runny) |
| Interproximals | Lab handpiece; Robinson #11; Tripoli Rouge |
| High shine | Dental lathe; cotton buff; Ivoclar Vivadent Universal Polishing Paste |
| Condition / cleanup | Mineral oil; fresh Robinson #11; steamer and/or soap + toothbrush + warm water |
Technique: Polish at low speed. Do not let wheels dry out — heat can damage flexible resin.
7. Process Controls
| Gate | Do not proceed if | Proceed when |
|---|
| Intake | Case missing or files unreadable in Medit Lab | Case open with matching ID / Rx |
| Scan QC | Holes, missing bite, inadequate soft tissue | Scans usable for design |
| Printer | Flex base queued to Pro / Pro S | Flex base on Pro 2 only |
| Design | Not Lab Technician–approved; below minima | QC-A pass |
| Resin | Expired or wrong material | In-date Apex Flex + Apex Teeth; shaken 1 minute |
| Wash | IPA < 91% | ProWash S standard multi-cycle |
| Pre-cure | Part wet; base supports already removed | Fully dry; base supports still on |
| Cure | Wrong cycle / classic ProCure for Flex base | NanoCure Apex Flex Denture complete |
| Outbound | Failed QC-E; not bagged; not logged | Bagged + SEAZONA outbound ready |
8. Procedure
A. Intake & scan QC
1
Open the case in Medit Lab.
2
Verify patient/case ID, arch, and prescription notes (Flex shade, teeth shade, due date).
3
Perform scan QC: required arches captured; bite usable; soft tissue/ridge adequate; no critical holes or wrong-patient files.
4
QC-SCAN: Pass → continue. Fail → stop manufacturing; request rescan or clarified Rx from the office. Do not design on failing scans.
B. Design (Heygears portal)
5
Import accepted scans into the Heygears portal.
6
Heygears designs the flexible partial per prescription (clasps, teeth, shade targets).
7
Export print-ready STL files (base + teeth for Duo).
8
Lab Technician approves the design for print.
QC-A: Clasps ≥ 1.2 mm; walls meet minima; occlusion reasonable; shades correct; STLs labeled.
If QC-A fails — return to Heygears for redesign; do not nest.
C. Nest (RayWare + Duo Kit)
9
Import approved STL(s) into RayWare.
10
Select Duo Mode on Pro 2.
11
Tank I: Partial denture base / Apex Flex — intaglio toward platform; anterior ~60°. Auto-orient is acceptable for most cases.
12
Tank II: Denture teeth / Apex Teeth — occlusal toward and parallel to platform.
13
Confirm supports: intaglio and interproximals clear of supports; adequate supports for success. Edit manually only if needed.
14
Send to the Pro 2 queue. Flex base must not be aimed at any printer other than Pro 2.
Fallback if Duo unavailable: sequential Flex then Teeth jobs at 100 µm — document in SEAZONA.
D. Print
15
Confirm Apex Flex and Apex Teeth are not expired.
16
Shake Apex Flex for 1 minute. Pour to at least the minimum fill line. Record lot in SEAZONA.
17
Shake Apex Teeth for 1 minute. Pour to at least the minimum fill line. Record lot. Stir/filter tank resin if already poured.
18
Install and lock Duo Kit adapter, platform, and tanks. Protect tank bottoms when off the printer.
19
Assign the correct material to each tank/side on the touchscreen.
20
Confirm the build platform is clean and free of debris or cured resin.
21
Optional: preheat resin. After preheat, start within 15 minutes or the printer will re-preheat.
22
Start print from the queue (typically ~32–40 minutes at 100 µm — trust printer status).
23
When complete, wait for the safety lid lock to disengage. Remove the Duo Kit platform carefully.
24
QC-B: Fully formed; no delamination; inspect before wash. Fail → remake.
E. Wash & dry
25
Install the Duo Kit wash adapter in ProWash S. Seat the Duo Kit platform securely.
26
Run Standard Multi-Cycle Wash with IPA ≥ 91% (3 min wash / 3 min rinse / 3 min dry per Apex Flex IFU).
27
Keep teeth on the build platform during wash. Base may remain on the platform or wash in the basket.
28
Fully dry base and teeth with compressed air — especially tooth sockets, grooves, and internal surfaces. Residual IPA interferes with bonding and final cure.
QC-C: Clean and fully dry. Do not assemble or cure wet parts.
29
Remove parts for assembly. Leave supports attached to the denture base through assemble/tack and until after NanoCure.
F. Assemble & post-cure
30
Roughen sockets or tooth bases if needed for bond.
31
Load Apex Flex into a syringe; apply into each tooth socket.
32
Seat teeth with firm, even pressure; tack-cure until teeth no longer move. Do not remove base supports before final cure.
33
Place the assembled RPD in NanoCure fully dry (supports still on). Select Apex Flex Denture and follow on-screen prompts.
If base and teeth are from different resin lines, select Conventional Denture instead.
Do not use classic ProCure for Flex bases.
34
After full cure, remove supports. Be careful around clasps. Prefer support snips; cut close to contact points. Remove the posterior support bar with snips.
QC-D: Cured, bonded, clasps intact. Fail → remake or salvage per remake criteria.
G. Finish, clean, bag (end of procedure)
35
Smooth remaining support contact points with a carbide bur at low RPM.
36
Polish using the SprintRay Master Workflow sequence: Resilience (B27/B29) → Tripoli (Robinson #11) → Ivoclar Universal paste (cotton buff) → mineral oil → fresh Robinson #11 cleanup. Low speed; keep wheels wet.
37
Clean with soap, toothbrush, and warm water (and/or steamer); dry. This is lab cleaning — not chemical disinfection.
38
Label and bag the prosthetic for outbound delivery from the in-house lab.
39
Complete the SEAZONA case log; mark status bagged / ready for outbound.
QC-E: Finish OK; cleaned; bagged; labeled; SEAZONA complete. Do not release if QC-E fails.
End of SOP-LAB-030. Office receipt, chairside disinfection before try-in, and patient delivery are handled under clinical protocols — not this manufacturing procedure.
9. Case Log (SEAZONA)
| Field | Entry |
|---|
| Date | |
| Patient / case ID | |
| Medit Lab reference | |
| Arch | ☐ Max ☐ Mand ☐ Both |
| Scan QC | ☐ Pass ☐ Fail → returned |
| Designed by (Heygears) | |
| Design approved by (Lab Technician) | |
| Apex Flex shade + lot | |
| Apex Teeth shade + lot | |
| Printer / Duo used | Pro 2 / Duo ☐ Yes |
| ProWash S cycle OK | ☐ Yes |
| NanoCure cycle | Apex Flex Denture ☐ |
| Lab Technician initials | |
| QC-SCAN + A–E pass | ☐ Yes |
| Remake? | ☐ No ☐ Yes — reason: ________ |
| Bagged for outbound | ☐ Yes — time ________ |
No SEAZONA bagged status = not released from the lab.
10. Quality Checkpoints
| ID | When | Pass | Fail action |
|---|
| QC-SCAN | After Medit Lab intake | Scans usable | Return to office |
| QC-A | Pre-print | Approved design + minima | Return to Heygears |
| QC-B | Post-print | Complete geometry | Remake print |
| QC-C | Post-wash | Clean + dry | Re-wash/dry |
| QC-D | Post-cure | Bonded + cured | Remake / salvage |
| QC-E | Before outbound | Finish + clean + bag + SEAZONA | Hold release |
11. Remake Criteria
| Finding | Action |
|---|
| Failed scan QC | Do not manufacture — request new scans |
| Incomplete print / missing clasp / delamination | Remake print |
| Flex base printed on non–Pro 2 | Remake on Pro 2 |
| Wet / under-cured / wrong cure cycle | Hold outbound; correct or remake |
| Teeth debond during finish | Re-bond and re-cure if appropriate; otherwise remake |
| Torn or thin clasp after supports | Remake |
| Light support nubs only | Salvage — finish and re-check QC-E |
| Unsure | Stop and escalate to Doctor / lab lead |
12. Competency
A Lab Technician may run this procedure unsupervised after:
| Requirement | Sign-off |
|---|
| Read SOP-LAB-030 and Job Aid SOP-LAB-030-JA | Tech __________ Date ______ |
| Demonstrates Medit Lab intake, scan QC, Heygears portal submit/export/approve, and process controls | Trainer __________ Date ______ |
| Completes 3 observed cases to bagged outbound with SEAZONA log | 1. ______ 2. ______ 3. ______ |
| Trainer attests ready | Trainer __________ Date ______ |
| Lab lead authorizes unsupervised production | __________ Date ______ |
13. Troubleshooting & Escalation
| Problem | Action |
|---|
| Bad scans in Medit Lab | QC-SCAN fail → return to office |
| Print failure | Remake; filter resin; verify Duo / material assignment |
| Soft after cure | Confirm dry part and Apex Flex Denture cycle; remake if needed |
| Teeth debond | Re-bond or remake |
| Allergy or wrong indication noted | Stop — Doctor; do not manufacture |
Escalate to Doctor / lab lead: unclear indication, allergy, chronic remakes, IFU deviation requests.
Escalate to office (Medit Lab / SEAZONA): failed scan QC; missing prescription.
SprintRay Support: 1-800-914-8004 — missing NanoCure Apex Flex Denture profile; repeated Pro 2 failures.
14. References
- SprintRay Apex Flex IFU-029 Rev 2
- SprintRay Apex Teeth IFU-022
- SprintRay Master Workflow Guide — Partial Dentures (effective 10/13/2025)
- FDA 510(k) K250617
