Carbon, a leader in 3D printing technology, explains how Trey Ford’s digital investment turned a small lab into a high-throughput powerhouse.
In an industry where precision and efficiency define success, the ability to scale without sacrificing quality is the golden ticket. Yet, for many small to mid-sized dental labs, achieving this balance feels impossible. That was exactly the challenge facing Trey Ford, owner of Design Dental in Ohio, USA.
As competitors rapidly embraced digital workflows, Trey knew his traditionally run lab needed a serious upgrade to stay competitive. What he didn’t expect was just how transformative the right technology partner could be.
A lab on the brink of change
For years, Design Dental operated with a traditional, labour-intensive workflow. Dentures were crafted by hand, a meticulous and time-consuming process. By 2019, the lab was producing just 150 arches a year – a respectable figure but far from competitive in a rapidly digitising industry. Meanwhile, labs using digital printing solutions were delivering exponentially more cases, growing their businesses while keeping costs under control. It was clear: if Trey wanted to scale, manual processes alone wouldn’t cut it.
Carbon enters the picture
The turning point came when Trey invested in Carbon’s Digital Light Synthesis (DLS) technology. Unlike conventional 3D printing, Carbon’s approach offered the speed, precision, and consistency needed to scale denture production without compromising on quality. But this was more than just a hardware upgrade – it was a fundamental shift in how the lab operated.
The results were staggering:
- 2019: 150 analogue arches, four employees, one denture technician
- 2021: 326 digital arches, five employees, one technician handling design and finishing
- 2022: 641 digital arches, six employees, one designer, one finisher
- 2023: 1,142 digital arches, eight to nine employees, one designer and design service, one finisher.
With just one finishing technician, Design Dental increased their output more than sevenfold in four years, proving that digital adoption isn’t just about working faster – it’s about working smarter.
Scaling smart, not just big
One of the most significant advantages of integrating Carbon’s printers wasn’t just raw production numbers; it was efficiency. Despite increasing output sevenfold, the lab only slightly increased its staffing.
Instead of hiring a team of finishers, Trey’s team relied on the high level of accuracy from Carbon’s prints, which required far less manual post-processing. The quality was so consistent that rather than adding multiple finishing technicians, the lab’s first priority hire in 2024 was a second finisher who also operates the printers – doubling productivity without dramatically increasing costs.
More than just numbers – a cultural shift
The impact of digital transformation went beyond numbers and staffing. With streamlined workflows, the lab introduced a four-day workweek, improving work-life balance while maintaining productivity. The shift to a digital-first approach fostered a more innovative, agile team – one that could take on more cases, work smarter, and push the boundaries of what a small lab could achieve.
Why scaling is easier than you think
The story of Design Dental isn’t just about one lab’s success – it’s proof that scaling doesn’t have to mean adding more people, more headaches, or more inefficiencies. With the right technology partner, labs of any size can unlock a future of rapid growth without the growing pains.
Whether you’re in London, Manchester, or anywhere in the UK, the barriers to digital adoption are lower than ever. If a small lab in Iowa can scale by seven times in just a few years, what’s stopping you?
Ready to see what’s possible? Contact the Carbon Dental Team at [email protected] and start your transformation today.
This article is sponsored by Carbon.
