(NEED HELP) Asiga Ultra Misprint Troubleshooting - NextDent BASE Resin

[Conson_Gib573]

My lab has had two NextDent 5100 printers for a few years now, and has just recently upgraded and received three Asiga Ultra printers. We wanted a more up-to-date printer, and have heard nothing but greatness about Asiga's printers. It has been a love story with the Ultra printer, and we have had great success so far when printing with most of our materials. Our only issue we have run into is when we're using NextDent's BASE resin.

I have had nothing but failed prints when using this resin with the Ultra and I have tried every troubleshooting step I can think of. I've tried many different orientations, support patterns, and micron thicknesses. I have tried using different bottles, made sure it was mixed properly, and have recalibrated the machine multiple times. The failures have ranged from supports not attaching to the build platform, the part having holes, and flaking in the final product. I've reached out to my reseller and Asiga themselves multiple times with no response yet. Searching for information on the internet has left me empty handed as well. In the past, we have gotten fantastic results using the "BASE" resin for full dentures and flexible partials, so I would like to stick with it if possible.

Side Notes: I did download correct material profile and imported it to Composer. I have also drained and cleaned the Endurance resin tray after every failed print, straining all of the used resin twice each time before reuse. When auto-generating supports, the software would "shotgun" blast the part with a bunch of supports, so much to where it makes post-processing a nightmare (and the print would still fail). Something I have also noticed is that my estimated print times have doubled on the Asiga Ultra when compared to my NextDent 5100 with that specific resin (compared it using the same denture base STL, same micron settings (50), same orientation, and using Asiga's FAST MODE). In my lab, we were averaging 1 1/2hrs - 2 1/2hrs for one base arch to print on the NextDent, and print time is VERY crucial for our application.

Im seeking any advice or tips from anyone! I'm completely out of ideas.

Thanks!

 

[DDE]

I have an ASIGA 4k printer, and I had the same issues with the flexible next dent base resin.

I tried everything and nothing worked, sometimes I got a good print but it took 2-3 attempts including recalibrating etc.

I had to give up in the end, Asiga couldn't resolve it, though they did replace the trays that were damaged during the prints.

Now I just print and bend wire. It's a shame as the material is great at what it does but it's just so damn unreliable.

 

[AaronW12321]

Give this a try, we've had a lot of issues printing dentures and this is what we've ended up with. It's not 5100 base resin, we use lucitone, but it is for an ultra. If you're ever having a problem with prints adhering to the platform, increase the "exposure time" by 10 seconds or so in the burn in layer column, keep increasing until they stick.

 

[LiamBra]

Hi, did you ever figure this out. We are trying to print NextDent Base on Asiga UV max and maybe 1 out of 10 print. Tried increasing bottom exposure, different supports, different angles just cant get it to work. Maybe its under exposed?

 

[erzdaemon]

To me this sounds like a material issue, i'd suggest reaching out to NextDent and ask for detailed printing instructions.

Maybe Check expiring date on the used resin.

There may be a newer Material ini for the Ultra on NextDent's Side, the ini on Asiga's site is 1 year old now.

 

[tuyere]

Yeah, at this point I'd be assuming it's underexposing for whatever reason, you can rule that one out by increasing exposure times (and particularly bottom exposure, if you're getting print-detachment failures) in the material profile, you can open them with Notepad / Notepad++ to edit. Just make sure to save them with the .ini extension so they get saved as the material profile format and not a normal text file.

 

[Conson_Gib573]

Hello all. Here is an in-general update on where I am at now and what I have learned.

Involving Failed Prints:
I have many photos here that shows the many failed prints I have had so far that shows my results so far.

I am not having problems with the prints sticking to the platform anymore, rather I am having my supports fail at random. I have had one or two successful prints at random, but even the successful prints are very flakey. I also believe that these failed prints have damaged all of my endurance trays in some form. Many have creases and noticeable dents in them.

Since my last post on this thread, I approached my reseller to see if their techs could fix the problem. No dice. Tech said that he had never seen any failed prints like this before and had no clue on how to fix it. He blamed the material profile being configured wrong by NextDent.

I attempted to contact NextDent directly, and they couldn't get any support from them. Now I am currently knocking on Asiga's door trying to get a solution. It has been a hit and miss with Asiga when it comes to them calling me back.

Im going to try and edit the exposure times some more to see if it helps, and I will keep you all updated. It seems that all these problems are stemming from it being such a flexible material, and that the material's ini file is not correctly configured.

Involving Print Times:
I have discovered that my NextDent 5100 uses "Figure 4 Technology", which allows for the printer to print crazy fast by printing multiple layers of the part at a time. Even though the printer is over 6 years old, it will always print circles around my Asiga Ultra. With my current denture base times averaging 1 1/2 hours for one full row of dentures (angled at 45 degrees) at 50mm thickness on my NextDent 5100.

My current times with my Asiga Ultra (when it successfully prints) for denture bases are averaging 4-5 hours with the same thickness and angle parameters while having FAST MODE enabled. Making the bases at 100mm with FAST MODE enabled lowers the time to 2 1/2 - 3 hours, but I have not had a single successful print using these settings.

Other Notes:
If anyone has any insight on a resin substitute that can serve as both a partial and full dentures, please let me know.

*I have looked into Dentsply's Lucitone resin, and it looks perfect besides one thing- the cure box I would have to buy. I am already in the weeds with these Asiga Ultra printers that we bought and that I cannot return. Trying to pitch investing that much more into these printers already would be an uphill battle. I also cannot find any information regarding Dentsply's material being flexible for partials. Anyone have any testimonies on using Lucitone resin for partials?

I will accept any tips or helpful information to get me out of this nightmare!

 

[erzdaemon]

Allthough they added the ULTRA to the NextDent BASE.ini, it seems to not be officially validated for the Ultra yet, but then again the ini is 1 year old so there should be someone at NextDent to make statement.

Asiga will most likely just add the download link and will not be responsible for it, allthough i am pretty sure they can help adjusting if you provide your photos and state that you didn't get help by NextDent yet, which may accelerate your problem solving

Try starting a ticket in your asiga account for that > https://myaccount.asiga.com/accounts/support/0/

You could try further by editing your .ini and adjusting like support overexposure and so on but that's shooting in the dark and there should be a good ini provided by nextdent.

What i would have tried would be a low force tray, which does not seem to be availlable for the Ultra, only the UltraGloss tray.

I would suspect the cause may be the huge build platform of the ULTRA causing heavier flows when seperating but that's also just a shot in the dark.