Introduction: Meeting a Persistent Clinical Need
Flexible partial dentures have long been a trusted solution for restoring aesthetics and function for partially edentulous patients. Traditionally, these dentures are fabricated using techniques such as waxing, investing, injection molding, and manual finishing. While effective, these analog methods are labor-intensive and rely heavily on skilled technicians—a workforce that is increasingly constrained. In fact, the fabrication of flexible partial dentures using injection molding and other conventional methods has been documented to require multiple precise manual steps, which can contribute to variability and longer production times (World Journal of Dentistry, 2012) and (PMCID: PMC10985649).
While injected resins demonstrate consistent mechanical strength, the analog fabrication process often introduces variability in fit, leading to remakes, prolonged turnaround times, and ultimately reduced patient satisfaction according to Phillip L J Keenan. On the other side, early 3D-printed single-cure resins offered speed, but often failed durability tests, leaving clinicians hesitant to adopt them according to 3D Printing and Molding Study in Polymeric Materials
With the launch of FP3D resin, developed in partnership between Carbon and Keystone Industries, this gap between strength of traditional injected resins with the speed and precision of 3D-printed resins has been closed. FP3D material is the first dual-cure 3D-printable resin for flexible partial dentures, combining digital precision with the mechanical reliability of injected materials.
The Shift from Analog to Digital Workflows
Traditional injected partials require multiple manual steps: pouring models, waxing, investing, burnout, acrylic injection, and finishing. Each of these steps introduces variability and consumes valuable technician time. According to the Dental laboratory technician demographics and statistics in the US study, 59% of Dental Technicians are over 40 years old. With a workforce already skewed toward older technicians and fewer new entrants, the reliance on labor-intensive workflows poses a growing challenge for labs and clinicians alike.
By contrast, FP3D™ solution enables a streamlined digital workflow:
Capture an impression or intraoral scan (no change to clinical process)
The lab designs the partial digitally in CAD software
The design is 3D-printed in FP3D resin
A post-print thermal cure and finishing produce the final appliance
A digital record is kept for future updates
This digital workflow removes multiple analog bottlenecks while maintaining the precision clinicians expect.
The Case for Choosing FP3D™ Resin
Seamless Adoption
Clinicians don’t need to alter their chairside workflows. Physical impression or intraoral scanning protocols remain unchanged; the digital transition occurs entirely within the lab
Accuracy & Fit
FP3D material utilizes the high print precision of Carbon DLS™ technology known for its accuracy reducing the copy error as compared to traditional analog fabrication*.
Durability You Can Trust*
Tested to last beyond 3 years, FP3D resin gives your patients confidence for long-term performance.
Natural Aesthetics
High translucency and multiple shade options (original pink, light reddish pink, dark veined) naturally blend with the patient’s mouth.
Biocompatibility & Safety
An FDA-cleared Class II medical device, FP3D flexible partial resin meets ISO standards for safety and performance.
Better Results
The enhanced retention, low water sorption, and improved polishability help you deliver natural results faster and more consistently than traditional methods*.
Seamless Digital Workflow
Digitized flexible partials and digital archiving provide precision, accuracy and efficiency, enabling clinical productivity.
*Data on file.
Dual-Cure Chemistry: A Breakthrough in Flexible Partials
For years, the trade-off was clear: injected resins delivered strength but demanded labor-intensive processes that led to variability and frequent remakes. Single-cure 3D-printed resins improved efficiency but were prone to failure. Labs and clinicians needed a solution that combined both durability and digital precision.
The answer arrived with Carbon’s proprietary dual-cure technology.
From the beginning, the team recognized that Carbon’s dual-cure chemistry—engineered to deliver exceptional durability without compromising print speed, precision, or economics—could be transformative. Still, knowing that single-cure workflows would be simpler for labs, we conducted extensive testing to explore that path. The results were conclusive: single-cure formulations simply couldn’t withstand the daily stresses of use.
Building on Carbon’s proven rigid polyurethane (RPU) chemistry, the team developed a UV-curable formulation that printed with precision and incorporated a thermally activated network to achieve the required stiffness and long-term durability. After more than 100 iterations, we refined the formulation to deliver the ideal balance of performance and simplicity.
From a materials science standpoint, FP3D resin’s key technical breakthroughs lie in its durability, elongation at break, and cyclic fatigue resistance. Yet labs have also highlighted an unexpected and highly practical benefit—its polishability. Unlike other flexible materials that tend to gum up polishing burrs, FP3D resin flakes away cleanly, behaving like traditional acrylic and making finishing faster and easier.
Dual-cure means predictability. It helps ensure that when a flexible partial is prescribed, the device performs reliably for over three years.
Why Clinicians Should Ask Their Lab for FP3D
By requesting FP3D resin, clinicians gain access to a new standard of care for flexible partial dentures. Powered by Carbon DLS™ technology, flexible partials made with FP3D resin deliver exceptional accuracy, long-term durability, and natural aesthetics in multiple shades. FDA-cleared and biocompatible in accordance with ISO 10993, FP3D resin is designed to support safe, consistent, and efficient printing as well as designed to deliver precise fit, reliable retention and excellent polishability.
Conclusion
FP3D solution marks a turning point in prosthodontics. FP3D is not just another flexible partial resin. It is the first material to merge the efficiency of digital workflows with the proven durability of injected resins, giving clinicians a tool they can rely on for predictable results. By asking their labs to produce flexible partials with FP3D dual-cure resin, clinicians can deliver strong yet flexible, durable, and aesthetic restorations backed by FDA clearance and rigorous testing.