Let me be honest - when Cory Lambertson and Bryce Hiller from ASIGA joined me at 5 AM their time for our latest Digital Dentistry Decoded podcast, I knew we were in for something special. What I didn't expect was seven major product releases that could fundamentally change how we approach dental 3D printing.
Having tested countless 3D printers and materials over the years, I've become somewhat skeptical of "revolutionary" claims. But after our conversation, I have to say ASIGA's approach to solving real clinical problems while maintaining their open system philosophy is genuinely impressive.
The "Two Potato Problem" That Nobody Talks About
Here's where things get interesting. ASIGA identified a problem with curing units that, frankly, I hadn't even considered - but it makes perfect sense. As Bryce explained:
"Let's say you want a baked potato and you wanna just throw it in the microwave, and you wanna hit the timer for five minutes. When it comes out, it's cooked... Well, what happens if your husband or your wife or your kids also want a baked potato? Now you need to make three and you throw them in the microwave, you hit five minutes, they come out, they're not cooked."
The same principle applies to curing units. When you cure multiple splints or crowns together, they're competing for the same photons. ASIGA's new Cure unit features "scientific dose curing" with four internal sensors that automatically adjust curing time based on what's actually in the chamber.
In my experience, consistency in post-processing has always been a challenge, especially when it comes to shade matching. According to Cory, this technology ensures "if your material's supposed to be an A1, it's gonna be A1" - regardless of which ASIGA Cure unit you're using.
Print Pods: ASIGA's Answer to the Cartridge Revolution
Now, when it comes to the elephant in the room - yes, this is clearly ASIGA's response to systems like Midas. But here's what sets it apart:
Reusability: Unlike single-use cartridges, ASIGA's pods can be used up to five times. As someone who's watched colleagues drain Midas capsules trying to salvage expensive resin, this is a game-changer.
Open System: True to ASIGA's philosophy, these pods will work with materials from Keystone, VOCO, Dentsply Sirona, and others. Cory revealed they're even working with "companies that make amazing restorative materials that are composites" to develop 3D printable versions.
Cost Efficiency: We're talking $6-10 per unit cost, with pods priced at $20-35. That's remarkably competitive.
Versatility: The pods work with existing E.MAX printers - no need for dedicated hardware. As Bryce pointed out:
"Now you have one machine that can do it all, and it does it all very well."
Note: Older E.MAX models with clamping systems will need a simple 5-minute conversion kit to use the pod system.
The Materials That Actually Matter
What caught my attention was ASIGA's ability to print 80% filled ceramic materials - something I've struggled with on other systems. When I pressed them on how they achieved this, Cory explained:
"It's a combination of having an extremely well engineered machine that's strong and robust, and then combining it with a smaller build platform, which alters the approach and separation forces."
They even mentioned testing formulations close to 90% filled. That's lithium disilicate territory, folks.
Understanding ASIGA's Printer Portfolio
For those not familiar with ASIGA's lineup, here's the breakdown:
E.MAX: The compact "beast" that changed the game - ideal for chairside
Pro 4K: High-volume freestanding machine for labs
The Funnel and Genera software releases show ASIGA understands that hardware is only part of the equation. Funnel's automatic nesting and fleet management could save hours of "playing Tetris" with parts, while Genera addresses the model builder gap left by Medit's pricing changes.
At an estimated $0.25 per model, Genera is priced sensibly - something I appreciate after seeing other companies charge $20+ monthly for similar features.
Crown Kit: The Missing Piece Before Print Pods
Before we dive deeper into the pods, let's talk about ASIGA's Crown Kit - now available for all E.MAX and Ultra series machines. This enables printing 6-12 restorations in just 10-15 minutes. The real benefit? You can finally use those smaller material bottles instead of buying full kilograms of rarely-used shades.
As Bryce explained: "Let's say you've got a case that you need to print in a more uncommon shade. Like, let's say you've got like a D2 or a D3... you're never gonna print enough crowns to go through an entire kilogram of D2 or D3 resin."
E.MAX Two Gets Serious Upgrades
The updated E.MAX Two addresses two key issues:
- New slide lock mechanism: Replacing those fiddly spring clamps
- Enhanced heating: Now reaches 50°C (vs. previous 30-35°C), enabling higher viscosity materials
These might seem like minor updates, but they're essential for the more advanced materials ASIGA is now supporting.
New Materials at Competitive Prices
All four new materials are priced at $175/kg retail:
- Dent Tray Orange: Finally, contrast for blue impression materials
- Dent Retainer: Hard clear resin for Hawley-style retainers
- Dent Splint: Soft splint material that relaxes at body temperature
- Dent Flex: Flexible RPD resin
These prices are aggressive and show ASIGA's commitment to making 3D printing profitable for practices and labs.
The Reality Check on Direct Aligner Printing
I appreciated Bryce's honest take on aligner printing:
"I also try to stay in touch with reality and I think what a lot of people have realized is that when you factor in post-processing and the challenges of post-processing clear aligner materials, for a lot of people it still makes sense to just print the model."
Having tried printed aligners myself (they're sitting right behind me as I write this), I can confirm - they go cloudy after three days in the mouth. We're not there yet.
My Take: Open Systems Win
What strikes me most about ASIGA's approach is their commitment to openness. In an industry increasingly moving toward closed ecosystems, Cory's advice resonates:
"Always invest in open, whether it's your 3D printer or it's your intraoral scanner... make sure it's open so you're not locked in with anything and you'll ultimately be happier in the long run."
As someone who's dealt with the frustration of being locked into proprietary materials and workflows, this philosophy matters.
The Pod Wash: Simplicity Wins
ASIGA didn't stop at pods - they've also developed a shaker-based cleaning system. After printing, you simply:
- Remove the magnetic stem from the build platform adapter
- Place it in a test tube-like container with IPA
- Shake for 10 seconds
This eliminates the "white powdery defect" we often see when ceramic resins soak in alcohol too long. Sometimes the simplest solutions are the best.
- Crown Kits & Updated E.MAX Two: Available now
- Funnel Software: Q3 2025 (Southern Hemisphere), Q4 2025 (North America)
- Genera Software: Pricing details coming soon
- New Materials: Regulatory approval expected by year's end
- Print Pods: Limited availability late 2025, broader release early 2026
The Bottom Line
ASIGA has delivered what might be the most comprehensive product launch I've seen in dental 3D printing. They're not just responding to market disruption - they're creating their own path while staying true to their open system roots.
The Print Pod system, combined with their existing printer lineup, offers something unique: flexibility without compromise. You can print your morning's crown in a pod, then switch to printing models or surgical guides in the afternoon. No dedicated hardware, no locked materials, no nonsense.
Make no mistake - the landscape of chairside 3D printing is changing rapidly. But ASIGA's approach of solving real problems while maintaining openness gives them a compelling position in this evolving market.
As Cory wisely noted: "The most expensive piece of equipment you own doctors, the one that you're not using." With ASIGA's versatile approach, that's one problem you won't have.
Have you tried any of ASIGA's new releases? What's your experience with cartridge-based printing systems? Drop me a line at director@instituteofdigitaldentistry.com or let's discuss in the comments below.
