Why KeySplint Soft Resin is the Superior Choice for 3D-Printed Splints: A Deep Dive into Wear Resistance and Comfort
The Silent Epidemic: Why Occlusal Splints Matter More Than Ever
Bruxism—the involuntary grinding and clenching of teeth—is a pervasive issue affecting millions of adults worldwide. Often occurring during sleep, it is frequently exacerbated by stress and anxiety, leading to an increase in patients presenting with signs of severe tooth wear, fractures, and debilitating Temporomandibular Joint (TMJ) disorders.
For decades, dental professionals have relied on occlusal splints and nightguards as the primary defense against these destructive forces. A well-designed splint protects the dentition, alleviates muscle tension, and helps manage TMJ pain. However, the effectiveness of this treatment is heavily dependent on the material used to fabricate the appliance.
The Shortcomings of Traditional Splint Materials
Historically, the dental industry has depended on two main categories of materials for splint fabrication: heat-processed acrylics and thermoformed sheet materials. While functional, both present significant clinical challenges.
Heat-Processed Acrylics (e.g., PMMA): Traditional hard acrylics are rigid and durable, but they come with inherent flaws. In the aqueous environment of the mouth, these materials can experience monomer leaching. Over time, this degradation causes the acrylic to become increasingly brittle, significantly raising the risk of fracture under the heavy occlusal loads of a bruxing patient. This brittleness ultimately reduces the service life of the appliance and can lead to unexpected breakages.
Thermoformed Sheet Materials: Often used for dual-laminate or soft splints, these materials have a high glass transition temperature (Tg), meaning they remain rigid at all temperatures. While they may offer initial comfort, their lack of thermal flexibility makes insertion and removal difficult for the patient. Furthermore, under cyclic loading, thermoformed materials are highly susceptible to brittle fracture, micro-cracking, and edge fracture. In fact, localized wear testing has shown that dual-laminate materials can exhibit catastrophic volume loss and deep wear facets when subjected to simulated clinical wear.
The dental industry has long needed a material that combines the durability required to withstand bruxism with the flexibility needed for patient comfort and longevity. This is where the next generation of 3D-printed resins, specifically KeySplint Soft®, changes the paradigm.
What Is KeySplint Soft? A Revolution in 3D-Printed Splints
KeySplint Soft® by Keystone Industries, available through 3DNA Dental, represents a paradigm shift in the fabrication of dental appliances. This patent-pending, DLP-optimized 3D printing resin is specifically engineered for the digital production of flexible splints, nightguards, mouthguards, repositioners, and bleaching trays. As an FDA-cleared Class II medical device intended for professional use, KeySplint Soft ensures that dental practices and laboratories can deliver safe, compliant, and high-quality appliances to their patients.
What sets KeySplint Soft apart is its unique formulation that perfectly balances the strength required to protect against severe bruxism with the flexibility needed for superior patient comfort. The material is fully biocompatible, transparent, and highly polishable, resulting in an aesthetic appliance that patients are more likely to wear consistently. Furthermore, it is stain-resistant and easily cleaned by the patient, ensuring long-term hygiene and clarity. The resin boasts a guaranteed three-year shelf life and remains color-stable over time, preventing the yellowing often seen in traditional acrylics.
At 3DNA Dental, KeySplint Soft is available in multiple configurations to suit the specific needs of any dental lab or practice. The resin is offered in three distinct colors: Clear (1kg), Blue (0.5kg or 1kg), and Pink (1kg). Validated on multiple open-source 3D printers, KeySplint Soft integrates seamlessly into existing digital workflows, providing a highly efficient and profitable solution for modern dental professionals.
The Science of Dual Behavior: Rigid Outside, Comfortable Inside
At the heart of KeySplint Soft's unique performance is its advanced thermo-responsive material science. Unlike traditional acrylics or thermoformed sheets that maintain a constant rigidity, KeySplint Soft is engineered with a glass transition temperature (Tg) of approximately 50°C. In polymer science, the glass transition temperature is the critical point where an amorphous material shifts from a hard, glassy state to a softer, more pliable, rubbery state. Because 50°C sits perfectly between room temperature and the temperatures required for thermoforming, the resin exhibits a remarkable "dual behavior" that transforms how splints function both on the bench and in the patient's mouth.
At room temperature, KeySplint Soft is rigid and holds its shape exceptionally well. It boasts a flexural modulus of approximately 1,100 MPa. This high modulus means the material is stiff enough to be easily handled, polished, and adjusted by dental professionals outside the mouth without warping or losing its precise fit. It provides the structural integrity needed to withstand the forces of bruxism and protect the dentition.
However, the true magic happens when the splint is inserted into the patient's mouth. Warmed by body temperature, the material becomes noticeably more pliable, with its flexural modulus dropping to around 120 MPa. This dramatic reduction in stiffness translates directly to clinical benefits: the splint becomes flexible enough to comfortably adapt to the patient's unique dental anatomy. This flexibility not only makes insertion and removal significantly easier for the patient but also eliminates the tight, uncomfortable feeling often associated with rigid acrylic nightguards.
Inside the Research: The Creighton University Wear Study
When selecting a splint material, clinical longevity is just as important as patient comfort. To put KeySplint Soft® to the test, Keystone Industries sponsored an independent study led by Dr. Mark A. Latta, Dean Emeritus and Professor of General Dentistry at the Creighton University School of Dentistry. The 2021 study rigorously evaluated the wear resistance of seven different splint materials under simulated clinical conditions.
The methodology utilized a Leinfelder wear simulator to replicate the localized contact wear that occurs in the mouth. Twelve specimens of each material were mounted in a stainless steel fixture and subjected to an 80 N vertical load. To mimic the abrasive environment of the oral cavity, the test was conducted in a water bath containing a slurry of unplasticized PMMA beads. Each material underwent 400,000 cycles, which is equivalent to approximately three years of clinical wear.
The results revealed fascinating insights into how different materials handle wear:
|
Material
|
Volume loss (mm³)
|
Max depth (µm)
|
|
KeySplint Hard™
|
0.322 ± 0.066
|
343.2 ± 54.7
|
|
Lucitone Clear Acrylic
|
0.347 ± 0.095
|
418.5 ± 143.6
|
|
2mm Splint (sheet)
|
0.430 ± 0.117
|
994.8 ± 336.1
|
|
Standard Clear PMMA Disc
|
0.720 ± 0.334
|
1468.9 ± 545.6
|
|
KeySplint Soft®
|
1.138 ± 0.168
|
646.6 ± 99.8
|
|
KeySplint Soft Clear for Carbon®
|
1.238 ± 0.432
|
681.8 ± 129.1
|
|
Dual laminate 2mm
|
3.643 ± 1.141
|
2844.1 ± 860.7
|
While KeySplint Soft® showed a higher volume loss (1.138 mm³) compared to traditional rigid materials like Lucitone Clear Acrylic, its maximum wear depth (646.6 µm) was significantly lower than that of the 2mm splint sheet (994.8 µm) and the standard PMMA disc (1468.9 µm).
The Science of Energy Absorption: Why KeySplint Soft's Wear Behavior Is Actually a Strength
When evaluating materials for bruxism appliances, dental professionals often look at wear resistance as a primary indicator of longevity. However, this apparent paradox—higher volume loss but shallower wear depth—is actually a testament to KeySplint Soft's superior energy-absorbing behavior.
Scanning Electron Microscope (SEM) imaging from the study showed that KeySplint Soft undergoes plastic deformation under stress without cracking. Instead of fracturing, the material yields slightly, spreading the wear evenly across the surface. This dynamic flexural property prevents the formation of deep, localized wear facets that can compromise the structural integrity of the appliance.
Conversely, traditional thermoformed sheets and PMMA materials exhibited micro-cracking, brittle fracture, and edge fracture under the same localized wear testing. The dual laminate 2mm material performed the worst, with a staggering volume loss of 3.643 mm³ and a maximum depth of 2844.1 µm. When a rigid material cannot absorb the energy of bruxism, that force must go somewhere—often resulting in catastrophic failure of the appliance or transferring the stress to the patient's temporomandibular joint (TMJ) and dentition.
It is also crucial to note that the traditional acrylics and sheet materials in the study were tested under ideal conditions, without the effects of hydrothermal aging or water storage. In a real-world clinical environment, traditional acrylics are prone to monomer leaching in aqueous conditions, causing them to become increasingly brittle over time. KeySplint Soft's dynamic modulus ensures that it maintains its energy-absorbing properties, providing a durable, comfortable, and long-lasting solution for patients suffering from bruxism.
Digital Workflow Advantages: 3D Printing vs. Traditional Splint Fabrication
The shift from analog to digital dentistry has revolutionized how we create dental appliances. Traditional methods—such as hand-processed acrylics and thermoformed sheets—are often labor-intensive, prone to human error, and generate significant material waste. By integrating KeySplint Soft® into a fully digital workflow, dental professionals can unlock unprecedented levels of efficiency, precision, and patient satisfaction.
The digital workflow for 3D-printed splints follows a streamlined, predictable path: scan → design → print → post-process (wash/cure) → polish. It begins with an intraoral scan, which captures the patient's dentition with exceptional accuracy. This digital file is then imported into CAD software to design a custom splint with precise occlusal contacts and optimal thickness.
Once designed, the appliance is 3D printed using KeySplint Soft resin. Because KeySplint Soft is validated on multiple open-source, DLP-optimized printers, dental labs and chairside practitioners have the flexibility to produce high-quality splints in-house. This capability drastically reduces turnaround times, making same-day delivery of custom splints a reality.
Beyond speed and accuracy, the digital workflow offers unparalleled reproducibility. If a patient loses or damages their splint, there is no need for a new impression or a lengthy refabrication process. The original digital file is securely stored and can be reprinted on demand with the exact same fit and specifications. Furthermore, 3D printing is an additive manufacturing process, meaning it only uses the exact amount of resin required, significantly reducing material waste.
Clinical Applications, Practical Tips & Conclusion
KeySplint Soft® has revolutionized the fabrication of dental appliances by combining the strength required to withstand severe bruxism with the flexibility needed for optimal patient comfort.
Versatile Clinical Applications
•Nightguards for Bruxism: The material's energy-absorbing behavior prevents brittle fracture, effectively protecting teeth against the intense forces of grinding and clenching.
•Occlusal Splints and Bite Planes: It provides reliable therapy for TMJ disorders and cases requiring tooth immobilization.
•Mouthguards and Repositioners: The flexibility at body temperature ensures a snug, comfortable fit that adapts to the patient's unique anatomy.
•Bleaching Trays: Its transparent and stain-resistant properties make it an excellent choice for aesthetic treatments.
Conclusion: The Superior Choice for Dental Professionals
The 2021 Creighton University wear study clearly demonstrates that overall clinical longevity is defined by more than just wear resistance; it requires a balance of function, utility, and durability. KeySplint Soft's innovative formulation prevents the micro-cracking and brittle fracture common in traditional acrylics and thermoformed sheets. By choosing KeySplint Soft, dental professionals can provide their patients with appliances that are not only highly effective but also exceptionally comfortable and long-lasting.
Ready to elevate your practice with the next generation of 3D-printing resin? Purchase KeySplint Soft Splint Resin at 3DNA Dental today! For any questions or support, contact the 3DNA Dental team at (813) 263-3038 or email paul@3DNADental.com.
Frequently Asked Questions (FAQ)
Q: Is KeySplint Soft suitable for severe bruxism?
A: Yes, KeySplint Soft possesses the strength to withstand severe bruxism. Its energy-absorbing properties prevent the brittle fracture often seen in traditional hard materials, offering both durability and comfort.
Q: How should patients clean their KeySplint Soft appliances?
A: Patients should clean their appliances daily using a soft-bristle toothbrush and cold water. Mild cleaning agents, such as Dawn dish soap, are also validated for safe use.
Q: What sizes and colors are available?
A: KeySplint Soft is available in 0.5kg and 1kg bottles. Color options include Clear (1kg), Blue (0.5kg or 1kg), and Pink (1kg), allowing for customization based on patient preference.
Q: Is the material safe for long-term intraoral use?
A: Absolutely. KeySplint Soft is fully biocompatible, complies with international medical device regulations, and is an FDA-cleared Class II medical device designed for extended wear in the mouth.
References:
[1]: # "Latta, M.A. (2021). A Laboratory Evaluation of Localized Wear of Splint Materials. Creighton University School of Dentistry: Center for Oral Health Research."
[2]: https://3dnadental.com/products/keysplint-soft-splint-resin "3DNA Dental. KeySplint Soft Splint Resin."
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