For more than 90 years, ROE Dental Laboratory has built its reputation on embracing innovation while maintaining an unwavering commitment to quality. Founded in 1933 and headquartered in Independence, Ohio, ROE Dental has grown into a full-service dental laboratory serving clinicians across all 50 states. Today, with approximately 290 employees and a dedicated digital design team, ROE remains at the forefront of digital denture manufacturing.  

"We adopted concept of digital denture workflows at the onset of the technology's introduction," says BJ Kowalski, CEO of ROE Dental. "We continue to make progress with different systems and materials, finding solutions that suit different patients' needs and demographics."  

As ROE searched for new ways to improve efficiency, consistency, and scalability in denture production, the company found an answer in the NextDent 300 MultiJet 3D Printer and 3D Systems' Jetted Denture Solution. 

Returning to a Trusted Partner 

ROE's relationship with 3D Systems stretches back decades. Long before today's digital workflows became mainstream, the laboratory was already experimenting with additive manufacturing technologies. 

"In the early days of 3D printing, we had ProJet printers from 3D Systems," Kowalski explains. "Our first 3D printer from 3D Systems was used to print simple wax crown and bridge copings. Later, as the next generation of new machines evolved to printing resin, we expanded it's use for castable patterns and later for surgical guides."  

After working with a range of digital manufacturing technologies over the years, ROE revisited 3D Systems when evaluating options for large-scale 3D printed denture production. What immediately captured their attention was the ability to manufacture multi-material, monolithic dentures without the assembly steps traditionally associated with 3D printed denture workflows. 

"We were interested in the NextDent 300 because it allowed us to do something in on piece, avoiding the assembly process of other digital denture production options," says Kowalski. "Having a one-piece prosthesis saves time and allows technicians to focus on more complex case work."  

ROE was also intrigued by the ability to print multiple tooth shades in a single build, opening new possibilities for efficient customization. 

Simplifying Production While Improving Consistency 

Many laboratories evaluate new manufacturing technology primarily through the lens of print speed. For ROE, however, the true value of the NextDent 300 extends well beyond the printing process itself. A full tray of dentures can take approximately 10 hours to print, yet Kowalski notes that overall turnaround times remain highly competitive because the post-processing workflow is significantly streamlined. Traditional assembly, bonding, and cleanup steps are eliminated or greatly reduced.  

"The process itself is a little time consuming, but because of the assembly time and cleaning time it normally takes, we can turn around products as fast or faster than we could before," he says. Even more important is the predictability the workflow delivers. "From digital design to printed prosthesis, there's really no chance for error," Kowalski explains. "It's a very predictable process." 

That consistency has become especially valuable when reproducing dentures for existing patients. Unlike workflows that rely on the precise alignment and bonding of multiple components, ROE can generate exact replicas directly from the digital design file. 

"If we need to reproduce a denture, we're getting an exact replica because it's precisely what we printed before," says Kowalski. "I think it's the most accurate way to make a full, exact duplicate of a denture that was previously made." 

Built for Production Scale 

 Across its network of facilities, ROE Dental produces many hundreds of dentures each day, requiring manufacturing systems that can keep pace with demand while maintaining consistency across locations.  

To support that growth, ROE recently expanded its fleet of NextDent 300 printers from four to six units, with two operating in its Chicago facility and four in the Cleveland area. The company runs its production environments on nearly continuous schedules, with most printers completing two build cycles per day. The technology's scalability was a key factor in ROE's expansion plans. 

"We're keeping the equipment busy, but we always maintain some intentional capacity," says Kowalski. "I can see us purchasing more NextDent printers down the road for sure." 

The workflow also minimizes staffing requirements. The laboratory's digital design team can remain focused on case design, while a single operator at each facility manages nesting and production tasks. Post-processing consists primarily of wax removal, wet bead blasting, and polishing. 

"The process is pretty fast," says Kowalski. "And then it's just a standard denture polish at the end because the surface is finished to a pretty high level." 

Quality That Speaks for Itself 

While production efficiency is important, success ultimately depends on patient and clinician satisfaction. For ROE, customer feedback has been encouraging. "Generally, no news is good news," Kowalski says. "The market has been pretty satisfied with NextDent appliances, with virtually no reports of ear or breakage, we've had pretty good success so far."  

The laboratory has found that the 3D printed dentures require minimal aesthetic enhancement before delivery. Rather than relying heavily on manual characterization, ROE builds lifelike details directly into the digital design. 

"We really try to design the gingiva and the teeth to have a very lifelike appearance," Kowalski explains. "The stippling, rugae, patient name, and other details are designed into the denture so they show up in the 3D print without us having to add anything."  

For many of its digital denture offerings, the laboratory simply polishes the restoration and sends it to the clinician.  

Making High-Quality Dentures More Accessible 

Perhaps the most compelling aspect of ROE's adoption of the NextDent 300 MultiJet 3D printer is how it aligns with the laboratory's mission of making quality dental care accessible to a wider population. Kowalski believes the industry faces a growing need for denture solutions that balance quality, affordability, and efficiency. Many patients requiring dentures are part of underserved communities, on fixed incomes, or unable to pursue more expensive restorative options.  

"A lot of dentures are being made for patients who need value-priced solutions," he says. "Not everyone can get an implant-supported case or a highly customized multi-appointment bespoke denture, we offer these solutions but needed a quality value solution" The efficiencies gained through the NextDent 300 workflow allow ROE to manufacture dentures more cost effectively while preserving the quality clinicians expect. 

"NextDent gives us a price advantage because it's much more efficient for us to manufacture these," says Kowalski. "We pass that savings along to our clients."  He believes the technology represents an important step forward for the dental industry. 

"This is a solution that allows us to make a high-quality denture affordable to everybody who needs it," Kowalski says. "It's affordable, predictable, and consistent."  

Looking Ahead 

As digital dentistry workflows continue to evolve, ROE Dental Laboratory remains committed to investing in technologies that improve outcomes for clinicians and patients alike. The company sees continued opportunities for growth with the NextDent 300 platform and expects digital denture adoption to accelerate in the years ahead. For Kowalski, the value proposition is simple: deliver dependable, repeatable dentures at a price point that expands access to care without compromising quality. 

"I think the NextDent 300 solves a problem within the current production of dentures," he says. "It's a very consistent product, and I think it's a leap forward for dental manufacturing." 

This article reflects the experience and opinions of a single dental laboratory customer. Results, productivity improvements, cost savings, workflow efficiencies, and business outcomes may vary depending on individual laboratory operations, clinical practices, and other factors. Statements made by ROE Dental Laboratory do not constitute guarantees of performance, clinical outcomes, or economic benefits.