Dandy Launches Fusion™ Denture Hybrid Process, Combining Digital Precision With Conventional Acrylic Advantages

Sep 29, 2026 - Dandy, a leading digital dental lab in the United States, has released its brand-new Fusion™ Denture line. The product adopts a proprietary hybrid manufacturing workflow: digitally milled base combined with manual acrylic packing and finishing, designed to address the well-known limitations of fully 3D-printed dentures regarding durability and natural gingival aesthetics, offering an alternative removable prosthetic solution for clinics across the US.

As a major US digital dental service provider, Dandy is known for its in-house Dandy Vision intraoral scanning system, cloud case collaboration platform and automated production lines. Its existing digital denture protocol enables a two-visit clinical workflow. The newly launched Fusion series shifts away from the pursuit of fully automated manufacturing, and integrates digital technology with conventional acrylic processing.

Clinicians capture scans intraorally. Technicians collaborate with dentists on tooth arrangement and morphology design for case approval. The denture base is prefabricated digitally via robots and AI at the lab, followed by manual acrylic packing by experienced technicians for seamless monolithic restoration.

The portfolio covers three main removable categories: complete dentures, flexible partial dentures and implant overdentures. Flexible partials are available with Valplast and Duraflex materials for clasp-free designs. Dandy also announced that metal reinforcement mesh options for complete dentures will be rolled out in Q4 2026 to enhance fracture resistance. The base material selected is Lucitone® HIPA high-impact acrylic resin, paired with 3D-printed IPN teeth for reliable occlusal performance.

According to Cong Yu, Engineering Lead at Dandy, this solution marks a shift beyond the all-3D-printing era. Fully printed resin dentures have long presented two core clinical drawbacks: layered printing structures tend to create brittleness and higher fracture risk; printed gingival contours usually look flat with limited translucency, making it difficult to replicate the gradient, staining and dimensional depth of natural gingiva. Meanwhile, traditional packed acrylic dentures deliver lifelike texture and good toughness, yet suffer from inconsistent marginal fit, occlusal accuracy and variable outcomes tied heavily to individual technician skill, which often leads to extra adjustment appointments.

The Fusion hybrid process is engineered to offset weaknesses on both sides. The digitally fabricated base locks in seating accuracy and occlusal relationships for consistent results from case to case. Hand-packed acrylic, on the other hand, recreates the layered translucency, staining details and soft-tissue realism of natural gums.

Critically, it retains the biggest clinical benefit of conventional acrylic dentures: easy relining, repair and addition of replacement teeth, operations that are difficult or impractical on all-printed dentures. Original scan data is stored permanently, simplifying duplicate orders and long-term maintenance for patients.

Clinically, Fusion still fits into Dandy's signature two-visit workflow, cutting down the multiple try-in appointments required in conventional denture fabrication. Pricing starts at $259 for a full Fusion complete denture, with a turnaround time of approximately 5 business days.

This launch reflects an emerging trend within the US digital denture market: the industry is moving past the goal of full automation replacing traditional techniques, toward complementary hybrid workflows. Many labs and clinics rapidly adopted fully printed dentures in earlier years, but accumulating long-term clinical feedback has raised concerns over durability, repairability and soft-tissue esthetics. Fusion gives US practices a middle-ground option: keeping the efficiency and predictability of digital workflows while preserving the material benefits and serviceability of classic acrylic dentures.

Nevertheless, the hybrid model comes with challenges. It cannot run as a fully lights-out production line and requires a skilled team of packing technicians, making standardization harder than pure-print workflows. Variability in gingival staining and surface texture from manual packing remains a key factor to validate as the product scales.

Overall, Fusion does not reject digital denture technology. It represents a strategic adjustment of the development path: digital manufacturing handles precision and efficiency, while conventional manual acrylic packing delivers toughness and natural gingival esthetics. It is a noteworthy new removable prosthetic concept for dental OEM factories worldwide.