HeyGears to showcase dental 3D-printing workflows at Formnext 2026

Automation will be a major theme of HeyGears’ participation in Formnext. The company will present an end-to-end production approach for dental models and other applications, such as splints, denture bases, trays and surgical guides. The approach combines artificial intelligence-powered design and on-demand human design services with automated preprocessing, 3D printing and intelligent sorting. For high-volume production, HeyGears will present the UltraCraft A3D printer, which offers automated resin refill, automatic part removal and integration with HeyGears Cloud, its digital production management platform. The system is designed to support scalable production across multiple dental applications.

HeyGears will also demonstrate how HeyGears Cloud connects different stages of digital production. The platform can automatically consolidate orders, preprocess production files, distribute tasks among connected equipment and monitor production. In this demonstration, HeyGears Cloud will be linked with the UltraCraft A3D to illustrate how they work together throughout the production chain.

Another key attraction will be HeyGears’ One-Piece denture solution, which uses dual-material digital light processing. The UltraCraft MMF 3D printer prints and fuses denture base and tooth materials during a single printing process, producing an integrated one-piece denture without the need for adhesive bonding between separately printed components. Through this technology, HeyGears aims to break traditional manufacturing barriers and redefine digital dentures with a new category that brings together fit, comfort, natural aesthetics and structural reliability.

HeyGears’ One-Piece denture solution is designed to improve structural integrity and stability and to reduce sites for bacteria to accumulate. Aesthetics are equally central to the workflow. The One-Piece denture solution is designed to preserve tooth morphology and lifelike details for a natural-looking result. In addition to HeyGears’ own materials, the Lucitone Digital Print Denture resins from Dentsply Sirona are validated for use with the solution, offering users a broad selection of tooth and gingival shades.

HeyGears will also showcase its high-transparency workflow based on the UltraCraft A2D HD desktop 3D printer, the HT Resin Tank and the Pulsing Release Module, an optional accessory designed to reduce peeling forces during printing. The combination supports applications such as splints and flexible dentures.

For splint fabrication, the high-transparency workflow is designed to produce highly transparent, glossy surfaces directly through 3D printing, reducing or eliminating the need for manual polishing. In HeyGears laboratory testing using Keystone Industries’ KeyPrint KeySplint Hard Clear and the HeyGears HT Resin Tank, light transmittance reached up to 88%. Optimised washing and post-polymerisation are intended to help maintain clarity and consistency.

The same focus on aesthetics and production efficiency extends to flexible dentures. By combining multi-shade transparent resins with high-transparency printing, the workflow is intended to create a more natural appearance while providing the flexibility, rebound and durability required for everyday use. High-precision 3D printing and streamlined post-processing further simplify production, enable pre-polished results and reduce hands-on finishing.

Dental professionals can find out more about HeyGears’ workflows and attend live demonstrations at Booth C01 in Hall 12.1. More information can be found at heygears.com.