HeyGears' UltraCraft MMF technology fuses denture base and teeth in a single DLP print, eliminating bonding steps for better fit and aesthetics.
A New Chapter for Digital Dentures
HeyGears unveiled its One-Piece Denture Solution at LMT LAB DAY Chicago 2026, introducing a workflow that prints a complete denture — base and teeth — in a single, uninterrupted DLP build. Powered by the UltraCraft MMF (Multi-Material Fusion) printer, the system does away with the adhesive bonding that traditional split-print workflows rely on.
Molecular-Level Fusion, Zero Bonding
Rather than assembling separate components, the UltraCraft MMF achieves fusion between the two materials at a molecular scale, creating a seamless interface with no visible boundary. This improves retention strength and structural reliability compared with conventional bonded approaches, while also producing a smoother surface that is easier to clean and less prone to plaque build-up.
Precision Occlusion Out of the Box
Internal testing across 15 cases showed that all results landed within 0.8 mm of target elevation, with more than half within 0.5 mm. By contrast, split-bonded dentures often require 20–30 minutes of chairside occlusal adjustment to correct deviations of 2–3 mm. With the One-Piece workflow, dentures can typically be seated without any adjustment at all.
Lifelike Aesthetics, Consistent Results
Because the tooth morphology is preserved throughout the single-print process, anatomical detail and natural contours remain intact. This structural fidelity means high-quality aesthetic outcomes can be achieved with minimal manual finishing, delivering consistent results across cases.
What It Means for Dental Labs
The One-Piece Denture Solution is designed to streamline lab workflows, reduce production steps, and open new revenue opportunities for dental businesses. It represents HeyGears' push toward fully integrated, assembly-free digital denture production — setting a higher bar for precision, hygiene, and patient comfort.
