Laser Sintered Appliances
All-Metal Sintered Hawley
A Hawley with the palate, clasps and bow printed as one piece of metal — thin, rigid and impossible to snap at a solder joint.
DigitalScan or impression
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Digital · Laser sintered
Printed from the scan.
Seated in one visit.
Expanders, holding arches and bands printed in metal from your intraoral scan. No separator appointment, no band fitting, no solder joints — a one-piece frame that fits because it was built on the tooth it sits on.
No separators
Band position is designed into the file, so nothing has to be wedged between the teeth first.
No band fitting
Each band is printed to the scanned tooth, not chosen from a tray of sizes and pushed to fit.
No solder joints
Bands, arms and connectors print as one piece. The joint that used to fail is not there.
Why sintered
What changes when the band is printed, not fitted.
Fit comes from the scan
The band follows the actual clinical crown, undercuts and all, because it was built on it. Path of insertion and interproximal clearance are resolved on screen, not in the chair.
Two appointments become one
The separator visit and the band-fitting visit go away. The patient comes in for records and again to seat the appliance.
Lower profile, less bulk
A printed band is only as thick as it needs to be, and the connector can be shaped to the palate rather than bent to reach it. Patients notice.
One piece, no weak point
A soldered joint is where a conventional expander breaks. A sintered frame has none. The screw is the only separate component.
An exact remake, any time
The design file is kept with the case. A lost or damaged appliance is reprinted from the same file, without a new impression.
Faster in the chair
Seating a printed appliance is cementing, not fitting. The published technique reports a shorter delivery appointment and fewer of them.
How it is made
Scan to seated, in five steps.
The work moves from your scanner to our design screen to the printer, and only then to the bench. Everything a technician used to do with a band pusher is decided in the design.
- 01
Chairside
Scan
A full-arch intraoral scan that captures the clinical crowns of the abutment teeth. Add a bite if the design needs one.
- 02
Design
Build it in CAD
Band coverage, connector path and screw position are designed on the scan. Coverage is placed to clear the interproximal contact and the gingiva.
- 03
Print
Laser sinter
Metal powder is fused layer by layer into the finished frame — cobalt-chrome as standard, stainless steel where you want chairside adjustability.
- 04
Bench
Finish and fit the screw
Supports come off, the frame is polished, and the expansion screw or auxiliary is fitted. Every piece is checked against the scan before it ships.
- 05
Delivery
Seat and cement
A thin layer of band cement on the fitting surfaces and the appliance seats in one motion. No separators, no wedging.
What we sinter
Most banded designs. Without the bands.
If it was banded, it can usually be printed. Prescribe the appliance as you normally would and tick sintered; if a design is a poor candidate we will tell you before we start.
Two metals
- Cobalt-chrome
- The standard. Rigid, corrosion-resistant and biocompatible, with the strength to carry an expansion screw without flexing. The right choice for most expanders and arches.
- Stainless steel
- A little more give, which means a band can be adjusted chairside and auxiliaries weld to it cleanly. Ask for it when you want adjustment loops or expect to tune the fit.
Not sure which? Say so on the prescription and the case desk will call with a recommendation for the design.
3D printed 3D printed 
Laser Sintered Appliances
Sintered Nance
Nance holding arch printed as one frame — bands, palatal wire and button base — with acrylic added at the bench.
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Laser Sintered Appliances
Sintered Rapid Palatal Expander
Bands, arms and connector printed as one frame from the scan, with the expansion screw fitted at the bench. No separators, no band fitting.
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Laser Sintered Appliances
Sintered Space Maintainer
Band-and-loop and distal-shoe designs printed in one piece — no solder joint at the loop, no separator for the child.
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Laser Sintered Appliances
Sintered Distalizer Anchorage
Printed anchorage for pendulum and distalizing designs, with the springs and acrylic added at the bench.
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Sintered Habit Appliance
Tongue crib or habit cage printed with its bands as one frame.
DigitalScan or impressionLearn moreStart a case3D printed Laser Sintered Appliances
Sintered Herbst Anchorage
Printed crowns and bands for Herbst anchorage, with the telescopic hardware fitted at the bench.
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Sintered Lingual Holding Arch
Lower holding arch printed as a single frame from the scan, sized to the arch it will sit in.
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Sintered Quad Helix
Quad helix on printed bands with lingual sheaths, so the helix can still be removed and adjusted chairside.
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Sintered Transpalatal Arch
TPA with bands and arch printed together; the omega loop is designed in, not bent in.
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At the chair
Seating a printed appliance
It cements like a banded appliance and comes off like one. The difference is that nothing has to be fitted first.
Cement
A thin, even layer on the fitting surfaces. A coloured compomer band cement makes clean-up and later removal easier.
Surface
Self-etching primer on the lingual enamel before cementing improves retention on the partial-coverage design.
Seating
One motion, fully seated. The occlusal windows over the first molars let you confirm it is down.
Removal
A standard debanding plier through the occlusal window, exactly as you would remove a banded expander.
What to send
A good scan is the whole case.
- A full-arch scan with the clinical crowns of every abutment tooth fully captured
- Opposing arch, so coverage can be checked against the occlusion
- A bite registration where the design calls for one
- The prescription: design, screw type, anchorage teeth, anything to avoid
- Material preference if you have one — cobalt-chrome or stainless steel
Send directly from iTero, 3Shape, Sirona Connect or DS Core. Add Gergen’s as a recipient in the scanner software and the case arrives here without an export.
Send the scan. We’ll print the appliance.
Prescribe the design you already use and ask for it sintered. If you want to talk a first case through, the case desk will.