Case Study: New England Orthodontic Laboratory achieves reliable, high‑throughput thermoforming production with Carbon

Major orthodontics laboratory trusts Carbon’s dental solution for thermoforming applications

New England Orthodontic Laboratory, an experienced orthodontics lab, faced chronic printer failures, high maintenance overhead, and edge‑accuracy distortions from stereolithography and polymer‑jetting technologies that reduced throughput by 10–25% in some months. Seeking a dependable solution for 3D‑printed thermoforming models and functional appliances, the lab selected Carbon’s dental solution—deploying M Series printers running Carbon’s Digital Light Synthesis (DLS) technology under Carbon’s subscription model.

Carbon provided on‑site training, 100% inclusive service and support, and a production workflow that enabled New England Orthodontic Laboratory to start printing models, retainers, and expanders within a week and produce more than 1,300 thermoforming models and appliances in the first month. The Carbon solution eliminated printer failures and maintenance overhead, removed edge distortions, delivered best‑in‑class per‑part costs, increased throughput by 33% versus polymer jetting (five full arches in ~1.5 hours versus 3–4 hours), and led the lab to order two additional M2 printers and a Smart Part Washer.

New England Orthodontic Laboratory

Christian Saurman

Vice President