The dental industry has been witnessing a quiet revolution over the past decade, with digital technology fundamentally reshaping prosthetic dentistry. DP Zero Lab, part of Italy's Dental Pro Group, placed an early bet on that future—and it's paying off in ways founders Matteo Adorno and Federico Milano couldn't have imagined back in 2008.
When Matteo and Federico first opened their laboratory doors, it looked like most small dental labs across Italy. The space was modest, the equipment was entirely analog, and the two partners handled much of the work themselves. Traditional techniques dominated every aspect of production, from impressions to final prosthetics.
But even then, the partners saw something others missed. Digital technology wasn't just another tool; it represented a fundamental shift in how dental prosthetics could be designed, produced, and delivered. They started small, converting just 5-10% of their workflow to digital processes, learning as they went.
Those early years were about building expertise and proving the concept. Could digital methods match the quality of traditional craftsmanship? Could they scale? The answers would come, but first, they needed to grow.
In 2013, Matteo and Federico formed a partnership with Dental Pro Group. This relationship transformed the business overnight. Case volume increased dramatically, and with it came the need for more staff, more space, and more sophisticated systems.
The timing couldn't have been better. 3D printing technology for dental applications was maturing rapidly, and the materials were catching up to the promise of the hardware. This convergence of opportunity and capability allowed DP Zero Lab to accelerate their digital transformation in ways that wouldn't have been possible just a few years earlier.
The team expanded to 24 professionals, each bringing specialized skills to different aspects of the digital workflow. The physical space grew to accommodate new equipment. But the most dramatic change was in the workflow itself as analog processes steadily gave way to digital ones, month by month, year by year.
Transitioning from 10% digital to 97% digital didn't happen by accident. It required methodical planning, significant investment, and a willingness to experiment with new approaches.
The laboratory invested in Stratasys 3D printing systems, specifically chosen for their reliability and the quality of their materials. This was a strategic decision about which technology partner could support the lab's long-term vision.
Training became a constant priority. As new equipment arrived, staff needed to master not just operation but troubleshooting, material handling, and quality control specific to 3D printed applications.
Digital workflows also meant rethinking the production pipeline. Files needed to move seamlessly from dentist to lab to printer. Quality checkpoints shifted from physical inspections to digital verification. Even the relationship with dental practices evolved with more practitioners adopting digital scanning.
With their digital workflow humming along smoothly, Matteo and Federico decided to tackle one of dentistry's most demanding applications: complete denture prosthetics.
Full dentures present unique challenges. They need to fit precisely, look natural, and function comfortably for eating and speaking. Traditional denture fabrication involves multiple appointments, adjustments, and a considerable amount of skilled handwork.
To move to a digital denture workflow, the team developed a reliable protocol, documenting every step, and creating clear guidelines for their partner dentists. Not all practitioners adopted the new approach immediately—change is always difficult—but most eventually came on board as they saw the results.
"We put together a simple protocol to follow with Federico, and the doctors are following us," Matteo explains. "Not all of them, but almost—almost all of them. And the results are good."
The success of DP Zero Lab's digital transformation hinges significantly on their choice of technology. Stratasys’ J5 DentaJet 3D printing solutions combined with their TrueDent digital denture materials offered capabilities that made the ambitious workflow possible.
The J5’s full-color printing capability proved crucial. Dental prosthetics need to look natural, matching the subtle variations in tooth color and gum tissue that make them virtually indistinguishable from natural dentition. The J5’s full color PolyJet printing delivers this realism in ways that other 3D printing technologies struggle to match.
Precision matters enormously in dental work. Margins measured in microns determine whether a prosthetic fits comfortably or causes problems. The dimensional accuracy of the J5 DentaJet printers meant fewer remakes and adjustments, reducing both costs and patient inconvenience.
Speed was another game-changer. What once required multiple manual steps spread over days could now be accomplished in a fraction of the time. Faster turnaround times save significant labor time in the lab and mean that patients get their prosthetics sooner, reducing the time they need to go without teeth or managing with temporary solutions.
"Thanks to the evolution of the printers, to Stratasys and the TrueDent materials, we have a good product," Matteo notes. "The clinics, the doctors, and especially the patients are very happy with this."
The digital transformation of DP Zero Lab shows up in multiple ways, from daily operations to patient outcomes.
Walk into the laboratory today and you'll see a dramatically different operation than existed in 2008. Banks of 3D printers run continuously, producing prosthetics with minimal manual intervention. Digital files flow through networks instead of physical models moving from station to station. Quality control happens on computer screens as often as on benches.
The staff structure evolved too. The team now includes specialists in digital design and 3D printing operations.
Production capacity increased substantially. The lab handles far more cases than would be possible with purely analog methods, even with an expanded team. This scalability proved essential as their partnership with Dental Pro Group brought steady growth in case volume.
But perhaps most importantly, the clinical results have been strong. Dental practitioners report that prosthetics produced through the digital workflow fit well and require fewer adjustments. The protocols Federico and Matteo developed work reliably when followed, giving dentists confidence in the process.
Patients notice the difference too. The natural appearance of 3D printed dentures addresses one of the biggest concerns people have about getting dentures—that they'll look artificial. The fit and comfort issues that often plague traditionally-made dentures occur less frequently with the digitally produced versions. Patient satisfaction reflects this improvement.
DP Zero Lab's journey reflects larger trends reshaping dentistry across Europe and beyond. Digital workflows are becoming the standard rather than the exception, and laboratories that fail to adapt risk being left behind.
For dental practices, partnering with a digitally-capable lab like DP Zero changes what's possible. Treatment timelines compress, patients spend less time in the chair and outcomes improve.
The environmental impact deserves mention too. Digital workflows generate less waste than traditional methods. Materials are used more efficiently and the carbon footprint of shipping physical impressions back and forth is eliminated when digital scans can be transmitted instantly.
Matteo and Federico aren't treating their 97% digital workflow as a finish line. They see it as a milestone on a continuing journey.
Current research focuses on expanding the range of cases that can be handled entirely through 3D printing. Toronto bridges, complex prosthetic solutions for full-arch restoration, represent the next frontier. These demanding cases currently require zirconia milling, but advances in printing materials may soon make them viable for additive manufacturing.
Similarly, individual crowns and bridges remain predominantly milled from zirconia blocks. But as printing materials improve in strength and aesthetics, the team believes these applications will increasingly shift to printed production. The advantages of 3D printing—design freedom, reduced waste, faster production—apply just as much to these cases as to dentures.
"I expect that in the near future we'll arrive at a material that solves Toronto cases, or that solves cases of bridges and crowns that we now make in zirconia," Matteo says. "The path we've taken is definitely to grow with digital technology, with 3D printing, and to increase production as well."
DP Zero Lab's experience offers insights for other dental laboratories considering similar transitions.
First, commit early and completely. Half-measures in digital transformation often fail. Adorno and Milano's willingness to invest significantly in technology, training, and process redesign created momentum that carried through challenges.
Second, choose technology partners carefully. The relationship with Stratasys proved crucial, providing not just equipment but ongoing support, material development, and a roadmap for future capabilities.
Third, bring dental practitioners along. The best digital workflow fails if dentists don't follow protocols or trust the process. DP Zero Lab invested time in education and relationship-building, earning buy-in from their partner practices.
Fourth, expect iteration. The full denture protocols didn't work perfectly from day one. Success came from systematic refinement based on real-world results.
Finally, view digital transformation as continuous rather than complete. Technology keeps advancing, and staying at the forefront requires ongoing investment and learning.
DP Zero Lab's story is really about the future of prosthetic dentistry itself. As 3D printing technology continues to advance and more laboratories adopt digital workflows, patient care will improve across the board.
Prosthetics will become more accessible as production costs decrease and efficiency increases. Turnaround times will continue to shrink, reducing patient inconvenience. Quality will become more consistent as automated processes eliminate human error.
The next decade will likely see innovations we can barely imagine today. New materials will unlock new applications. Integration with intraoral scanning will become seamless. Perhaps most exciting, personalization will reach new levels as digital design tools make it easy to customize every aspect of a prosthetic to individual patient anatomy and preferences.
For now, laboratories like DP Zero show what's possible with vision and dedication. Matteo Adorno and Federico Milano's journey from a small analog shop to a digitally-powered operation demonstrates that transformation is achievable, but it requires commitment, investment, and a willingness to embrace change.
Founded in 2008 by Matteo Adorno and Federico Milano, DP Zero Lab is part of Italy's Dental Pro Group. The laboratory has been pioneering digital dental prosthetics, serving dental practices across Italy with 3D printed solutions and specializing in full dentures and other complex prosthetic applications. With 24 professionals and nearly complete digital workflow integration, the lab represents the cutting edge of modern prosthetic dentistry.
