We completed a 6‑week pilot on 12 banded RPEs using a 0.5 mm printed flexible liner as a palatal cushion, bonded to the acrylic shell, and saw fewer ulceration call-backs and easier seating on delivery. Customizing the pad geometry per scan — thinning under rugae and thickening along the midline — seemed to improve tolerance without affecting activation; is anyone else trialing flexible inserts, and what are you seeing for 3‑month wear and hygiene?
Using ‘0.5 mm’ here too; micro-perforate + prime acrylic to prevent week-3 delam; keep midline <=0.7 mm.
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Saw the same bump with VITA Easyshade V on #7–10, but , it still goes sideways if we skip a solid stump shade on darker preps — “zero staining tweaks” only holds when dentin isn’t fighting you. One tweak that helped: we average three middle‑third readings and add one cross‑polarized shot over a gray card (eLAB‑style, https://www.elabprime.com). Anyone seeing fewer remakes when you include ΔE with the scan instead of just A/B numbers?
We’ve been printing Shore 80 liners and switching to a scalloped 0.4 mm feather edge around the rugae, plus 0.6 mm “mushroom” wells in the acrylic underlay for mechanical lock — seating got easier and food traps dropped. @sophia68’s priming note tracks; a quick 50 μm Al2O3 sandblast and an MMA brush coat before bonding killed our week‑3 lift, but seal the margin with a thin Optiglaze layer or it gets funky like old sneaker insoles — are you seeing any odor?
We ran a small batch with a 0.5 mm liner and adding a 0.3 mm midline “saliva escape” channel made seating noticeably easier — like a tiny gutter. One caveat: stop the liner about 1 mm shy of the band shoulders or cement cleanup turns into archaeology, @maria_k.