Carbon Platform Improvements: February 2025

With printer software v1.42 (March/April 2024) and later, M3 and M3 Max printers will abort a print and alert the user if solid debris is detected in the resin at the start of a print. This functionality protects against hardware damage and print failures.

Based on continued analysis of print data and hardware damage, M3 and M3 Max printers running in Manual Mode will now use a more sensitive iteration of Debris Detection and abort prints in the presence of even smaller debris.

Reduction in M3 and M3 Max Print Time Variability for Rigid Resins

On M3 and M3 Max printers, print times for rigid materials have occasionally varied unpredictably. Carbon has made small adjustments to the way the printer responds to print forces to better handle these scenarios so that the incidence of unexpectedly long prints should be meaningfully reduced or eliminated, without an impact on print quality.

Improvements for Supports

Rafted supports (BETA)

A new option is available when generating patch supports: the “Base Raft” toggle automatically places supports closer together with large bases that connect many (or all) supports as a “raft.” To access this setting, navigate to Patch Supports and select a patch, then toggle “Base Raft” to ON before clicking “Generate All.”

Base Raft functionality has been developed to create supports compatible with automatic part removal using the AO Backpack, part of Carbon’s Automatic Operation suite of products, and thus has been tested primarily with certain types of supported dental models printed in DPR10. However, users are welcome to explore this BETA setting for other types of prints if desired.

Improved “regenerate supports” capability

When a user adds new support points or polylines to an already-supported part, then transforms the part in some way (such as scaling, rotating, moving on/off-platform) and opts to regenerate existing supports, the new supports (as indicated by new support points or polylines) will also be generated. In previous support regeneration requests, newly-indicated support points or polylines were discarded.

Expanded Range for Correction Scale Factors

The allowed range for Correction Scale factors has been expanded to 0.7–1.2 (from its previous range of 0.95–1.1) to accommodate a greater range of workflows.

Changes to Print Profile Options for Dental Labs

Additional Print Profiles universally available for DPR 10 prints

Two Print Profiles for use with DPR 10 are now available to all customers to provide dental labs with more control over print outcomes:

• DPR 10 Loosen Fit → Use this Print Profile for DPR 10 prints if, on previous prints, the fit of mating parts (for example, dies) is too tight
• DPR 10 Tighten Fit → Use this Print Profile for DPR 10 prints if, on previous prints, the fit of mating parts (for example, dies) is too loose

Workflow Improvements for the AO Backpack

More options for ending Automatic Mode

Customers with an AO Backpack now have more options for ending Automatic Mode:

• End Automatic Mode without physically visiting the printer.
• Pre-schedule the end of Automatic Mode based on a specific time or the number of completed prints.
• Opt whether to remove the final print’s parts or leave them on the platform.

Additional workflow improvements

Several elements of the AO Backpack have been improved for easier and more successful workflows:

• The machine can now distinguish between a parts bin that contains a basket and one that does not, and will warn the user if the basket is missing. Do not use the AO Backpack parts bin without the basket insert.
• Additional safety information is displayed for user confirmation when the blade is in cleaning mode (presented forward, with the printer door open).
• The resin refill system is more resilient in high-vibration environments.

Better Part Quality

AO Polishing Cassette for M3 and M3 Max Printers

Previously available only on M2 printers, Carbon’s AO Polishing Cassette expands its advanced light-scattering technology to the M3 and M3 Max platforms, enabling labs to achieve polished finishes directly during printing. This technology minimizes manual touchpoints, which can lead to reduced costs and increased throughput while maintaining exceptional part quality.

• Preserved Intricate Anatomical Details: Digitally designed features, such as gingival contours and palatal ridges, are maintained with minimal post-processing.
• Validated Materials:
  • Desktop Health^™ Flexcera^® Base
  • Desktop Health^™ SmileGuard^™
  • Keystone Industries^® KeySplint Hard^® Clear

Improved EPU Printing

Improved default print plans for elastomeric resins on L1, M3, and M3 Max printers

Certain parts printed in elastomeric resins (EPUs) on L1, M3, and M3 Max printers will have improved print outcomes and/or faster print speeds.

Improved print outcomes may be achieved for certain geometries with wide variation in size/dimension within a part or across a build (for example, a part that includes a lattice joined with a solid skin, parts with substantial supports, or a variety of different parts printed within a single build). Actual impacts will vary widely according to the specifics of the print, but in general, parts that were previously difficult or impossible to print successfully might now print more easily and/or with fewer defects.

Faster print times are possible for taller parts (generally >100 mm in height), with the largest decrease expected for parts that contain similar geometry throughout the part (such as a latticed seat cushion). The height and geometry of the part will impact the amount of time saved, with taller parts netting greater print time reductions. Importantly, print time improvements based on this change will not be incorporated in the print time estimate generated prior to printing.

EPU 46 printing improvements

In addition to the preceding general EPU printing improvements, these additional changes specifically aim to improve outcomes for prints in EPU 46:

• The default print plan now promotes stronger adhesion to the platform.
• Supports are automatically generated with wider tips and necks to promote better adhesion between the part and supports.

Protection Against Print Failures due to Cold Temperatures for DPR 10 and UMA 20 Aligner Model Prints (L1)

L1 aligner model prints in DPR 10 and UMA 20 will now enforce a minimum temperature threshold to protect against print failures. When temperatures in the production environment drop below a specific level, parts can suffer from adhesion failures. To avoid such failures, L1 aligner model prints in both DPR 10 and UMA 20 will now target 25°C (77°F) for all prints. When a print is started and the resin or printer is colder than the temperature setpoint, there may be a delay and a “heating” message displayed until the printer reaches the desired temperature. This heating process should last for <1 minute in most cases.

Check the full Printer Software v1.45 Release Notes for more details about many of the features discussed in this blog.

See November 2024 platform improvements here.