For years, the removable prosthetic market changed little. Labs and clinicians relied on traditional metal frameworks or flexible acrylics—options that worked, but often came with slow workflows and dated materials. That is finally changing with the rise of 3D printed flexible partials.
Denbright Dental Labs is leaning into this shift with BrightFLEX 3D. By moving away from analog processes, BrightFLEX 3D offers improvements across the board—from better fit and aesthetics to faster turnaround times and easier chairside adjustments.
In this post, we recap a recent Denbright webinar in which lab experts discussed why BrightFLEX 3D is becoming the new standard for practices looking to modernize their removable offerings and keep patients satisfied.
Why the Market is Ready for a Change
Traditional removable partial dentures (RPDs) have long been limited by:
- Analog impressions and inconsistent fits
- Time-intensive framework design and fabrication
- Brittle acrylic or metal clasps that fracture or irritate soft tissues
- Limited options for patients with metal allergies
- Long turnaround times and costly remakes
In a world where patients are increasingly accustomed to fast, aesthetic, and digitally customized solutions, the expectations for partial dentures are evolving.
“Most of the removable partials in the market are still made by hand, with multiple steps and multiple opportunities for error,” explains the Denbright webinar panel. “Digital printing brings consistency, repeatability, and an improved experience for both lab and clinician.”
What Makes BrightFLEX 3D Different?
BrightFLEX 3D is Denbright’s proprietary workflow and material system for producing flexible, biocompatible, 3D printed partial dentures.BrightFlex3D provides six key benefits:
1. 3D Precision Fit
Unlike traditional wax-ups or stone model duplications, BrightFLEX 3D leverages intraoral scans and digital design software to achieve a highly accurate fit. Each partial is customized to the patient's unique arch form and tooth structure, minimizing pressure points and maximizing comfort.
“The days of bulky, ill-fitting partials are over,” says the Denbright team. “Our digital design process ensures intimate adaptation to the tissue, with built-in relief zones where needed.”
2. Superior Strength and Durability
Using cutting-edge resin materials optimized for flexibility and toughness, BrightFLEX 3D partials deliver greater strength than traditional flexible partials. They’re more resistant to cracking, less prone to clasp breakage, and better able to handle occlusal load.
“We’ve tested BrightFLEX 3D against traditional Valplast-style flexible partials, and the results speak for themselves: higher fracture resistance and better long-term durability.”
3. Lightweight Comfort
Patients frequently report that BrightFLEX 3D partials feel lighter and more natural in the mouth. The digital design allows for streamlined thickness, reducing bulk without compromising structural integrity.
“The retention is excellent, and patients love how it disappears in the mouth, especially compared to bulky metal or acrylic options.”
4. Esthetic Advantage
BrightFLEX 3D partials use tissue-colored resins and avoid visible metal clasps, offering patients a more natural appearance, an especially important factor for anterior partials or younger patients.
5. 6-Day Turnaround Time
Digital workflows mean faster production. From scan to seat, cases can be turned around in as little as 6 lab days, making it a viable solution even for patients with time-sensitive treatment needs.
6. Easy Add-Ons and Remakes
Each BrightFLEX 3D case is digitally archived, making it easy to fabricate replacements, add teeth or clasps, or adjust existing designs without requiring new impressions.
What Clinicians Love Most About BrightFLEX 3D
The webinar featured real-world case studies and feedback from dentists who use the system.
Here’s what stood out:
Scan-Based Workflow
BrightFLEX 3D is optimized for practices using iTero or other leading intraoral scanners. The lab can receive files instantly and begin designing right away.
“Being able to scan for a partial, approve the design, and receive it in less than a week has changed how we treat patients,” one dentist shared. “It saves us a patient visit and delivers more confidence at delivery.”
Adjustability and Repairability
Though flexible, BrightFLEX 3D partials are easier to adjust chairside than older flexible materials, allowing for minor retentions or relining. Plus, repairs or relines can be made from archived digital files.
Patient Preference
Patients routinely choose BrightFLEX 3D over traditional options when presented with side-by-side comparisons. Comfort, appearance, and faster delivery are the top-selling points.
Ideal Indications for BrightFLEX 3D
BrightFLEX 3D is not a one-size-fits-all solution, but it works remarkably well in a broad range of clinical scenarios, including:
- Unilateral or bilateral distal extension partials
- Patients with esthetic concerns (no metal visible)
- Interim or transitional partials during implant planning
- Patients with metal allergies
- Cases where speed and cost are major factors
“It’s especially helpful for younger patients who don’t want metal in their smile, or for those waiting for implant healing but need something comfortable and functional in the meantime,” explains the lab team.
Clinical Workflow: From Scan to Delivery
Here’s what the typical BrightFLEX 3D workflow looks like:
Step 1: Digital Impression
- The clinician takes a full-arch scan with iTero or another scanner.
- The clinician ensures that soft tissues, edentulous areas, and the occlusal area are clearly captured.
Step 2: Design Approval
- Denbright’s removable design team creates a proposal using CAD software.
- The clinician reviews and approves the design via a secure link.
Step 3: 3D Printing + Finishing
- BrightFLEX 3D is printed using a proprietary flexible resin.
- Post-processing includes polishing and clasp tuning for retention.
Step 4: Delivery
- The case is delivered within 6 lab days.
- Chairside adjustments are usually minimal or unnecessary.
Step 5: Archiving
- Design file is saved for future modifications, remakes, or tooth additions.
Cost and Value: Affordable, Predictable, Scalable
BrightFLEX 3D is offered at a flat fee of $249 for up to 5 teeth, making it an affordable option compared to metal frameworks, without sacrificing quality.
This fixed pricing also helps practices more easily predict and present fees, especially when bundled into implant or transitional treatment plans.
The Denbright Advantage
Denbright Dental Labs, now a multi-lab platform with seven premier labs, has invested heavily in building best-in-class digital workflows across removable, restorative, and implant solutions.
With BrightFLEX 3D, they’ve created a scalable, streamlined, digitally driven removable offering that’s backed by:
- Removable specialists trained in digital design
- Fast turnaround and predictable scheduling
- Digital archiving for long-term patient value
- Support for intraoral scanner users (including iTero, Medit, and other leading intraoral scanners)
- Expanded training and clinical support for digital dentures and partials
Looking Ahead: A Digital Future for Removables
The rise of BrightFLEX 3D isn’t just about one product; it reflects a larger shift happening in the removable category:
- Digital design is replacing analog waxing.
- Flexible printed resins are outpacing metal and acrylic.
- Patient expectations are rising, and practices are adapting.
“Dentures and partials are no longer the analog stepchildren of digital dentistry,” the Denbright team concluded in the webinar. “With technologies like BrightFLEX 3D, they’re taking center stage.”
Ready to Upgrade Your Removable Game?
If your lab is still processing analog impressions for flexible partials, or if you’ve hesitated to offer removable options due to quality concerns, BrightFLEX 3D might be the modern solution you’ve been waiting for.
Clinicians can send a scan today and experience the workflow firsthand. Denbright also offers a removable consult line for treatment-planning support.
Learn More: denbright.com/brightflex-3d
About Denbright Dental Labs
Denbright is a platform of seven premium dental labs across North America, delivering high-quality, digitally driven solutions in removables, implants, esthetics, and restorative workflows. United by a mission to deliver brighter dentistry, Denbright supports private practices, DSOs, and clinicians of every specialty with advanced products, digital education, and personalized service.
