OnX Tough 2 Hybrids & Dentures
SprintRay OnX Tough 2 — Lab Manufacturing Procedure (monolithic)
DRAFT FOR REVIEW — not yet Doctor-approved for training.
Do not use for competency sign-off until Doctor releases this document.
Smile Avenue Family Dentistry — In-House Laboratory
SprintRay OnX Tough 2 — Lab Manufacturing Procedure (monolithic)
| Document ID | SOP-LAB-040 |
| Version | 0.1 DRAFT |
| Effective (target) | 09/10/2026 |
| Owner | Lab Technician (process owner) |
| Related | Station Job Aid SOP-LAB-040-JA |
Start: Case received in Medit Lab with scan QC
End: Prosthetic bagged and logged in SEAZONA for outbound delivery
1. Purpose
This procedure standardizes in-house manufacturing of SprintRay OnX Tough 2 prosthetics so every case meets the same quality, safety, and traceability standard before leaving the lab. OnX Tough 2 is a tooth-shade ceramic-hybrid resin used for hybrid denture prosthetics, implant-supported denture prosthetics, monolithic full and partial removable dentures, and preformed denture teeth for use in a denture (IFU-020_8).
2. Scope
In scope (lab manufacturing): Medit Lab intake → scan QC → send accepted scans / Rx to JB Dental → receive STL → Lab Technician design approval → RayWare / Pro 2 print (monolithic; no Duo Kit) → preferred IPA hand spray/wipe wash (or ProWash S alternate) → NanoCure OnX Tough 2 - Max Strength → finish / optional characterization → lab clean → bag & SEAZONA outbound log.
Indication forks covered in this SOP (per IFU-020_8):
| Fork | Appliance type | Notes in procedure |
|---|---|---|
| H | Fixed hybrid / implant-supported denture | Screw channels; T-bar if present; channel cleaning required |
| F | Monolithic full removable denture | Full-arch monolithic OnX; no Duo / no separate base resin |
| P | Monolithic partial removable denture | Partial-arch monolithic OnX |
| T | Preformed denture teeth | Teeth printed for later assembly into a denture base (separate base workflow) |
Out of scope: Chairside scanning technique; photogrammetry technique; clinical try-in, TiBase cementation, torque sequencing, and patient seat/delivery; chairside chemical disinfection; Apex Flex / Apex Teeth Duo Kit RPDs (SOP-LAB-030); Apex Base + teeth removable denture paths; Nightguards (SOP-LAB-020); Zest LOCATOR removable overdentures that use Apex denture resin (OnX applies only to LOCATOR fixed provisionals per Zest addendum); Duo Kit for OnX; non–SprintRay printers; inventing NanoCure exposure minutes.
3. Roles
| Role | Responsibility |
|---|---|
| Clinical Assistant / Office | Sends case via Medit Lab; receives bagged prosthetic from lab |
| Lab Technician | Scan QC; sends accepted scans / Rx to JB Dental; receives STL; approves design; manufactures; finishes; bags; SEAZONA log |
| JB Dental | Designs prosthetic per Rx; returns print-ready STL (VERIFY portal / email handoff method) |
| Trainer / Lead Lab Technician | Competency observation and sign-off (after Doctor release of this SOP) |
| Doctor | Clinical indication, shade/Rx, clinical delivery / try-in / remake authorization (outside manufacturing steps) |
4. Practice Configuration
| # | Item | Smile Avenue setting |
|---|---|---|
| 1 | Printer | Pro 2 only for this path |
| 2 | Cure unit (primary) | NanoCure — profile OnX Tough 2 - Max Strength (preferred per Master Workflow Guide 12/16/2025). Do not invent minutes — use on-device profile. |
| 3 | Cure alternate (if NanoCure unavailable) | ProCure 2 preprogrammed profile OnX Tough 2; or ProCure 60 min at 60°C (IFU only numeric ProCure cycle). Document alternate in SEAZONA. |
| 4 | Case intake | Medit Lab |
| 5 | Design | JB Dental designs; Lab Technician sends accepted scans / Rx; receives STL; Lab Technician approves before print. Doctor reviews at clinical delivery. VERIFY exact send/receive channel (portal vs email). |
| 6 | Duo Kit | Not used — OnX path is monolithic single-resin |
| 7 | Wash (preferred) | IPA ≥91% hand spray / wipe: 15 s spray+wipe → 30 s air dry → 15 s spray+wipe (IFU + MWG 12/16/2025) |
| 8 | Wash (alternate) | ProWash S Custom Cycle 3 / 0 / 3 (3 min wash, 0 min rinse, 3 min dry) |
| 9 | Shades | Bleach, A1, A2, B1, Hollywood White — select per Rx. VERIFY default if shade missing on Rx (soft suggestion: A2, consistent with teeth default on other SOPs). |
| 10 | Layer thickness | 100 µm (MWG Hybrid; RayWare typical default) |
| 11 | Min thickness | ≥ 0.5 mm (IFU) |
| 12 | Fit & Adjustment (RayWare Desktop only) | −100 µm for Hybrid Dentures (IFU). RayWare Cloud auto-sets Hybrid Denture parameters. |
| 13 | Lab clean before bag | Soap, toothbrush, and warm water (and/or steamer), then dry. Cleaning — not chemical disinfection. |
| 14 | Design approval before print | Lab Technician |
| 15 | Case log | SEAZONA |
| 16 | Characterization (optional) | Vita Akzent LC™ if stocked — VERIFY inventory. Final cure after characterization: IFU = ProCure 2 5 minutes. VERIFY NanoCure final-cure path if ProCure 2 not used. |
5. Safety
- Treat uncured OnX Tough 2 as a sensitizer. 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.
- Inhalation of high vapor: move to fresh air. Eye contact: rinse thoroughly. Ingestion: contact poison control.
- Do not substitute non-validated printers, washers, cure units, or resins for this path.
- Do not use expired resin. Store OnX Tough 2 at 15–25°C (60–77°F); protect from light; keep bottle/tank closed when not in use.
- Cure liquid waste resin fully before disposal. Follow hazardous-waste rules until cured.
- Contraindications (IFU): known allergy to ingredients; direct intraoral contact with resin that is not fully cured; any use outside indications for use.
6. Materials & Equipment
Resins
| Resin | Shades | Notes |
|---|---|---|
| SprintRay OnX Tough 2 | Bleach, A1, A2, B1, Hollywood White | Select per Rx. Soft default if unknown: VERIFY (suggest A2). |
Also: IPA ≥ 91%; optional Vita Akzent LC™ characterization kit; optional Clearfil Ceramic Primer Plus / TiBase cementation materials are clinical / placement — not required for bagged outbound under this SOP.
Equipment stack
| Step | System |
|---|---|
| Intake | Medit Lab |
| Design | JB Dental → STL to Lab Technician |
| Nest / print | RayWare → Pro 2 (standard platform; no Duo Kit) |
| Wash | Preferred: IPA hand spray/wipe; Alternate: ProWash S Custom 3/0/3 |
| Cure | NanoCure — OnX Tough 2 - Max Strength |
| Case log | SEAZONA |
Design QC targets (review JB Dental STL / design)
| Area | Minimum / rule |
|---|---|
| Wall / body thickness | ≥ 0.5 mm (IFU) |
| Orientation intent | Occlusal toward build platform; occlusal plane parallel; intaglio away |
| Fork H | Screw channels present and clear; T-bar recommended if self/other-lab design (MWG) |
| Fork F / P | Coverage / arch matches Rx; intaglio free of critical voids |
| Fork T | Tooth geometry complete; thickness ≥ 0.5 mm; shade matches Rx |
| Shade | Matches Rx (or documented VERIFY default) |
Finish kit
| Step | Tools / media |
|---|---|
| Support stubs | Fine lab carbide bur or abrasive fiber wheel until smooth/uniform |
| T-bar (if present, Fork H) | Lab handpiece + cutting disc |
| Characterization (optional) | Vita Akzent LC™; fine brush; handheld curing light (tack between layers); clear glaze on entire surface except intaglio |
| Final cure after characterization | IFU: ProCure 2 5 minutes (VERIFY practice device) |
| Lab clean | Brush, soap + warm water (and/or steamer); dry completely |
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 / fork type |
| Scan QC | Holes, missing bite, inadequate anatomy / tissue for design | Scans usable for JB Dental |
| Design handoff | Scans / Rx not sent; STL not received | STL received from JB Dental |
| Design approval | Not Lab Technician–approved; thickness < 0.5 mm | QC-A pass |
| Printer | Queued to any printer other than Pro 2; Duo Kit selected | Pro 2 monolithic path |
| Resin | Expired, wrong shade, or wrong material | In-date OnX Tough 2 shade per Rx; shaken 1 minute |
| Wash | IPA < 91%; preferred handwipe skipped without documenting alternate | Handwipe 15/30/15 or documented ProWash S 3/0/3 |
| Pre-cure | Part wet; screw channels (Fork H) still dirty/wet | Fully dry |
| Cure | Wrong profile / invented custom minutes | NanoCure OnX Tough 2 - Max Strength complete (or documented IFU alternate) |
| Outbound | Failed QC-E; not bagged; not logged | Bagged + SEAZONA outbound ready |
8. Procedure
Fork legend: Steps apply to all forks unless tagged [H], [F], [P], or [T].
A. Intake & scan QC
- Open the case in Medit Lab.
- Verify patient/case ID, arch, due date, and prescription notes:
- Indication fork: H fixed hybrid / implant-supported · F monolithic full · P monolithic partial · T preformed teeth
- Shade (Bleach / A1 / A2 / B1 / Hollywood White). If missing → VERIFY with office; soft default suggestion A2 until confirmed.
- Implant / screw-channel notes for Fork H; tooth count / clasp notes for Fork P; tooth set notes for Fork T. - Perform scan QC: required arches / tissue captured; bite usable when required; no critical holes or wrong-patient files.
[H] Confirm post-op / implant-related scan package is complete per Rx (tissue scan, photogrammetry package if practice supplies it — capture technique is clinical/out of scope).
[F]/[P] Confirm edentulous / partial scan set matches Rx.
[T] Confirm opposing / setup references needed for tooth design are present. - QC-SCAN: Pass → continue. Fail → stop manufacturing; request rescan or clarified Rx from the office. Do not send failing scans to JB Dental.
B. Design (JB Dental)
- Lab Technician sends accepted scans and prescription to JB Dental.
VERIFY: exact handoff method (portal login / upload URL / secure email). Document channel used in SEAZONA until practice locks one method. - JB Dental designs the prosthetic per Rx and returns a print-ready STL.
- Lab Technician receives STL and reviews against Rx and design QC targets.
- Lab Technician approves the design for print (Doctor reviews at clinical delivery — not a pre-print gate).
QC-A: Fork matches Rx; thickness ≥ 0.5 mm; shade correct; STL labeled; [H] channels/T-bar reviewed; [F]/[P]/[T] geometry complete.
If QC-A fails — return to JB Dental for redesign; do not nest.
C. Nest (RayWare — monolithic, no Duo)
- Import approved STL into RayWare (Cloud or Desktop).
- Select printer Pro 2. Do not select Duo Mode / Duo Kit.
- Job / material setup:
- Material: SprintRay OnX Tough 2 — exact shade per Rx.
- Thickness: 100 µm.
- Orientation: occlusal surface toward build platform; occlusal plane parallel; intaglio facing away.
- Supports: default structures.
[H] ≥ 3 supports on the incisal edge; no supports around screw channels.
[F]/[P] Default supports; keep intaglio clear of unnecessary supports.
[T] Default supports; preserve occlusal anatomy.
- RayWare Desktop only: set Fit and Adjustment to −100 microns for Hybrid Dentures (IFU). RayWare Cloud auto-sets Hybrid Denture parameters — verify job type/material.
- Send to the Pro 2 queue. Do not aim this path at any printer other than Pro 2.
D. Print
- Confirm OnX Tough 2 bottle is not expired and shade matches Rx / SEAZONA entry.
- Shake bottle thoroughly 1 minute. Pour into resin tank to at least the minimum fill line; stir tank resin. Record lot + shade in SEAZONA.
- Install and lock clean, dry build platform. Assign tank to correct material and shade on the touchscreen.
- Confirm platform is free of debris or cured resin.
- Start print from the queue. Monitor on printer touchscreen or SprintRay Cloud.
- When complete, wait for safety lid unlock. Remove platform carefully.
- Remove part with Print Removal Tool / scraper.
QC-B: Fully formed; no delamination; [H] screw channels patent; geometry matches nest. Fail → remake.
E. Support trim (pre-wash)
- Remove supports with flush cutters or round diamond disc; cut close to the device to minimize finishing. Small stubs may remain for later smooth.
[H] If printed with a T-bar, remove with cutters or lab handpiece + cutting disc (may finish residual at step G).
[T] Protect occlusal anatomy while trimming.
F. Wash & dry
- Preferred — hand spray / wipe (IFU + MWG; recommended for hybrids; use for all OnX forks unless documented alternate):
a. Spray IPA ≥91% and wipe with dry towel — 15 seconds.
b. Blow dry with compressed air — 30 seconds.
c. Spray IPA ≥91% and wipe again — 15 seconds.
MWG notes handwipe produces parts with ~40% better mechanical properties vs machine wash for hybrids. - Alternate — ProWash S: Custom Cycle 3 min wash / 0 min rinse / 3 min dry. Document “ProWash S 3/0/3” in SEAZONA when used instead of handwipe.
- [H] Screw channels: Spray each channel with IPA; clean with IPA-dipped micro applicator; compressed air until clean and dry. Repeat until channels are free of resin/IPA.
- Dry the part completely before post-cure.
QC-C: Clean and fully dry (channels dry for Fork H). Do not cure wet parts.
G. Post-cure
- Place dry prosthetic in NanoCure. Select profile
OnX Tough 2 - Max Strength. Follow on-screen prompts. Do not invent or override minutes.
If NanoCure unavailable: ProCure 2 profileOnX Tough 2, or ProCure 60 min at 60°C — document alternate in SEAZONA. - After post-cure, hand spray with IPA and wipe with dry towel for 30 seconds (IFU).
- QC-D: Fully cured; no soft spots; geometry intact. Fail → hold outbound; remake or escalate.
H. Finish, optional characterization, clean, bag
- Smooth remaining support stubs with fine lab carbide bur or abrasive fiber wheel until surface is smooth and uniform.
[H] Finish any remaining T-bar remnant with handpiece + cutting disc. - Optional characterization (recommended for aesthetics; VERIFY Vita kit stocked):
- Layer Vita Akzent LC™ stains as desired (e.g., gingival pink, incisal blue, character stains).
- Tack-cure between layers with handheld curing light.
- Apply thin clear glaze to entire surface except intaglio.
- Final cure after characterization: ProCure 2 for 5 minutes (IFU). VERIFY if practice uses another validated final-cure path.
Skip this step when Rx / time does not call for characterization.
- Lab clean: brush with soap and warm water (and/or steamer); dry completely. This is lab cleaning — not chemical disinfection.
Clinical disinfection before try-in/seat is an office/clinical step — not this SOP. - Label and bag the prosthetic for outbound delivery from the in-house lab.
Do not perform clinical try-in, TiBase cementation, or torque sequencing in this manufacturing run. - 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-040. Office receipt, chairside disinfection, try-in, TiBase/torque placement, 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 | |
| Indication fork | ☐ H hybrid/implant-supported ☐ F monolithic full ☐ P monolithic partial ☐ T preformed teeth |
| Arch | ☐ Max ☐ Mand ☐ Both |
| Shade (Rx) | ☐ Bleach ☐ A1 ☐ A2 ☐ B1 ☐ Hollywood White ☐ VERIFY default used: ____ |
| Scan QC | ☐ Pass ☐ Fail → returned |
| JB Dental handoff method | ☐ Portal ☐ Email ☐ Other: ____ (VERIFY) |
| Designed by (JB Dental) | |
| Design approved by (Lab Technician) | |
| OnX Tough 2 shade + lot | |
| Printer | Pro 2 ☐ (Duo Kit must be No) |
| Wash method | ☐ Handwipe 15/30/15 ☐ ProWash S 3/0/3 |
| NanoCure profile | ☐ OnX Tough 2 - Max Strength ☐ Alternate documented: ____ |
| Characterization | ☐ None ☐ Vita Akzent LC + final 5 min (device: ____) |
| 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 for JB Dental | Return to office |
| QC-A | Pre-print | Lab Tech–approved design + minima | Return to JB Dental |
| QC-B | Post-print | Complete geometry | Remake print |
| QC-C | Post-wash | Clean + fully dry (+ channels for H) | Re-wash/dry |
| QC-D | Post-cure | Fully cured on correct profile | Remake / escalate |
| 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 / delamination / closed screw channels (H) | Remake print |
| Printed on non–Pro 2 or with Duo Kit | Remake on Pro 2 monolithic path |
| Wet / under-cured / wrong cure profile / invented minutes | Hold outbound; correct or remake |
| Wrong shade vs Rx | Remake (or Doctor-authorized accept — document) |
| Thickness below 0.5 mm / critical voids | Remake |
| Light support nubs only | Salvage — finish and re-check QC-E |
| Unsure | Stop and escalate to Doctor / lab lead |
12. Competency
Competency sign-off begins only after Doctor approves this SOP for training (remove DRAFT banner).
A Lab Technician may run this procedure unsupervised after:
| Requirement | Sign-off |
|---|---|
| Read SOP-LAB-040 and Job Aid SOP-LAB-040-JA | Tech _ Date ___ |
| Demonstrates Medit Lab intake, scan QC, JB Dental handoff, RayWare nest, handwipe wash, NanoCure Max Strength, and process controls | Trainer _ Date ___ |
| Completes 3 observed cases to bagged outbound with SEAZONA log (include at least one Fork H if hybrid volume exists) | 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 |
| JB Dental STL delayed / missing | Confirm handoff channel (VERIFY); escalate to office / JB Dental; do not nest without approved STL |
| Print failure | Remake; filter resin; verify material/shade assignment; confirm Pro 2 (not Duo) |
| Soft / under-cured after NanoCure | Confirm part was dry; confirm profile OnX Tough 2 - Max Strength; remake if needed |
| Chalky surface after IPA | Avoid prolonged IPA dwell; re-finish carefully; document; remake if compromised (VERIFY whether older UK-guide chalk warning stays in training) |
| Screw channel blocked (H) | Re-clean with IPA + micro applicator + air before cure if still green; after cure may need remake |
| Allergy or wrong indication noted | Stop — Doctor; do not manufacture |
| Shade missing on Rx | VERIFY with office; do not guess permanently — soft hold suggestion A2 only until confirmed |
Escalate to Doctor / lab lead: unclear indication, allergy, chronic remakes, IFU deviation requests, clinical placement questions.
Escalate to office (Medit Lab / SEAZONA): failed scan QC; missing prescription / shade.
Escalate to JB Dental: redesign, missing STL, design QC-A fails.
SprintRay Support: 1-800-914-8004 — missing NanoCure OnX Tough 2 - Max Strength profile; repeated Pro 2 failures.
14. References
- SprintRay OnX Tough 2 IFU-020_8, DCO#1682 — Effective 12/06/2024
- SprintRay Master Workflow Guide — Fixed Hybrid Dentures — Effective 12/16/2025 (preferred wash/cure)
- Zest LOCATOR Denture Workflow Guide (2025-08-15) — OnX Tough 2 for fixed LOCATOR provisionals only; removable uses Apex
- SprintRay Hardware–Resin Compatibility chart (OnX Tough 2: Pro 2, ProWash S, NanoCure, ProCure 2)
- Research brief:
/workspace/sprintray-ifu/onx/OnX-Tough-2-SOP-Research-Brief.md
Smile Avenue Family Dentistry — In-House Laboratory · Internal use only
SOP-LAB-040 Version 0.1 DRAFT · Target effective 09/10/2026 · Not Doctor-approved for training
Review annually or when SprintRay IFU / equipment / design partner changes.