Post-Processing Guide for Senertek Splint Resin
From the printed appliance to a clear, polished finish
Once a splint comes off the 3D printer, post-processing begins. Remove residual resin from the outer and inner surfaces, trim support contacts, complete post-curing and polishing, and inspect the finished appliance. Understanding each step and recording the processing conditions helps keep production consistent.
A polished splint illustration alongside Senertek SPLINT V2 resin
Connecting printing and post-processing
The workflow covers centrifugal cleaning, support removal, internal resin cleaning, optional surface touch-up, UV post-curing under glycerin, polishing, and ultrasonic cleaning. Start with a test print and compare its actual dimensions with the CAD design.
Match wall thickness to the appliance's intended use and design requirements. Print a test appliance before batch production, compare actual wall thickness with the CAD model, and record the dimensional results.
1 Remove residual resin by centrifugation
Remove uncured resin from the printed surface using centrifugal cleaning. Do not use IPA, ethanol, or other alcohol-based cleaners in this workflow. Alcohol exposure can damage the surface, reduce transparency, increase yellowing, and cause microcracks.
Positioning the printed appliance in a basket for centrifugal cleaning
The equipment specification for this workflow is a 12–15 L compact washing/spin-drying unit rated at 150–250 W. A large plastic basket or modified grow basket accommodates the printed appliance. Secure the appliance and balance the load before operation. These ratings do not define rotational speed or treatment time; use the operating cycle specified for the actual resin-compatible equipment.
2 Carefully remove the support contacts
Briefly immerse the splint in 60–70°C water before support removal, then stabilize it and detach the supports with minimal force. This step is intended to ease removal and reduce cracking or tearing, especially around posterior regions. Inspect every contact area after trimming, and avoid prolonged heating or distortion.
Trimming support contacts on the outside of the printed appliance
3 Clean residual resin from the inner surface
Inspect the inner surface separately because it contains grooves and recesses. Use cleaning swabs or soft tools to remove residual resin, paying particular attention to internal surfaces, support attachment areas, and posterior regions. Recheck the inside even when the outside looks clean.
Cleaning inner recesses and posterior areas with a soft tool
4 Apply a thin, localized surface touch-up
For visible support marks, apply a very thin layer of Senertek Splint Resin to selected areas before final curing. This optional touch-up targets posterior regions, surface refinement, and cosmetic finishing. Keep the application localized and preserve the fitting surface, occlusal geometry, and designed thickness.
Do not conceal cracks or structural damage with surface touch-up. Photographs taken from the same angle before and after the step make changes in shape and finishing locations easier to compare.
Water used during cleaning
Use bottled drinking water rather than tap water for water-based cleaning and ultrasonic treatment. Minerals and calcium can contribute to cloudy or yellowish surfaces. Keep the water source consistent and record it with the other processing conditions.
5 UV post-cure under glycerin
Perform final UV post-curing with the splint immersed in glycerin. The glycerin barrier reduces oxygen inhibition at the surface and supports surface quality and transparency. Position the appliance so the required surfaces receive adequate exposure. A clear or hard-looking surface alone does not establish that the required cure has been completed.
Illustration of UV post-curing with the splint immersed in glycerin
Equipment power rating | Baseline UV post-curing time |
36 W | Approximately 15 minutes |
60 W | Approximately 6 minutes |
90 W | A shorter cycle may be possible; use the equipment-specific time |
Use approximately 15 minutes at 36 W or approximately 6 minutes at 60 W for the baseline profiles. A 90 W system may allow a shorter cycle, but no numerical duration is specified here. Power rating alone does not make different curing machines equivalent: match the model, wavelength, irradiation conditions, and product-specific minimum cure. Record the complete cycle.
6 Polish support contacts and surfaces
After post-curing, use denture polishing pads and fine polishing tools to finish contact points and rough areas. Polish only where needed while preserving the designed thickness and shape, then check for edge damage and cracks.
7 Ultrasonic cleaning and final inspection
After polishing, ultrasonically clean the appliance in bottled drinking water at approximately 80°C for approximately 5 minutes. Compare its shape and dimensions before and after treatment, and keep the cycle within the material's permitted heat exposure.
The optical finishing goals are reduced cloudiness, reduced yellow tint, and a cleaner surface. Clarity may continue to improve over the following hours. Record appearance, dimensions, and fit together rather than using transparency as the sole quality criterion.
Fit and exposure adjustment
When a test appliance is too tight and exposure is established as the cause, reduce exposure by 0.2 seconds. When it is too loose for the same reason, increase exposure by 0.2 seconds. Repeat the test print and measurement after each adjustment. Also check the design, support layout, and any distortion during post-processing.
Check LCD printer output regularly because exposure behavior can drift over time. For the pre-insertion warm-water step, briefly immerse the appliance at 60–70°C to temporarily increase flexibility and ease seating. Allow it to cool to a safe temperature before intraoral handling, and check that its intended shape and rigidity return after cooling. Never insert a hot appliance.
Final quality checklist
· A surface free of tackiness and visible residue
· Smoothly finished support contacts and edges
· Transparency and yellow-tint assessment
· Agreement with CAD dimensions and the required fit
· Absence of tearing, cracks, and distortion
· Recorded product, equipment, time, temperature, and processing conditions
Clarity is one of several quality criteria. Check that the required post-processing is complete, the designed shape is retained, and the final-use requirements are met. Recording these checks provides a consistent basis for comparing subsequent work.
Visit the Senertek website for product information and support.
Workflow settings at a glance
Use this summary alongside the step-by-step workflow. Record the actual equipment and cycle used for each appliance; specifications such as capacity or wattage do not replace equipment-specific operating settings.
Process | Settings and key requirements |
Product and design | Wall thickness 0.5–0.8 mm; optimal range 0.6–0.7 mm, subject to the appliance's design requirements |
Printing settings | LCD approximately 70°; DLP 80–85°; support contact diameter 0.3–0.4 mm |
Cleaning | No IPA, ethanol, or other alcohol-based cleaners; bottled drinking water for water-based stages |
Centrifugation | 12–15 L, 150–250 W unit; suitable basket; secure and balance the load; equipment-specific speed and time |
Supports and touch-up | Brief 60–70°C immersion before removal; optional very thin, localized application of the same resin |
Post-curing | Glycerin immersion; 36 W approximately 15 min or 60 W approximately 6 min; 90 W duration is equipment-specific |
Ultrasonic cleaning | Approximately 80°C for approximately 5 min; check dimensional and surface stability |
Pre-insertion treatment | Brief 60–70°C immersion; cool before insertion and verify shape and rigidity after cooling |
Exposure fine-tuning | If exposure causes tight fit: −0.2 seconds; if it causes loose fit: +0.2 seconds; retest after adjustment |
Managing yellowing
The baseline 60 W profile is approximately 6 minutes. A separate optical-adjustment example uses under 3 minutes at 60 W; it is not interchangeable with the baseline and must not override the product's minimum curing requirements. Use that shorter option only where the exact resin-and-device combination has an independently established adequate cure. Another adjustment is a longer ultrasonic cycle at approximately 80°C, within established heat-exposure limits. No extended duration is specified here. Assess dimensions and material performance as well as color.
Troubleshooting common surface and fit issues
Tacky surface: check residual resin and the curing cycle; insufficient cure may require additional curing and exposure of both sides using the product-specific procedure. Cloudy surface: check the water source and contamination, and use bottled drinking water. Poor fit: investigate exposure and dimensions, then adjust exposure in 0.2-second steps when appropriate. Yellowing: optimize the curing and ultrasonic cycles without undercuring or exceeding heat limits. A symptom can have more than one cause, so establish the cause before changing the process.
The five images are AI-generated workflow illustrations, not test results or equipment-performance evidence. Editorial basis: this article incorporates the requested assumption of expert sign-off; that assumption is not documentation of actual product validation.
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