Knapp Labs

“Looking Beyond Apparent Constraints” approach to additive manufacturing

knapp labs is aiming to redefine how monolithic zirconia crowns are made—moving beyond unesthetic, wasteful subtractive milling and multi-step staining/layering workflows to net‑shape, 3D‑printed, monolithic zirconia restorations with voxel level intrinsic shading designed to mimic surrounding natural dentition. Founded by Ken Knapp in 2021, Knapp Labs is targeting a 2026 market introduction (pending FDA approval to market) of its patent‑pending 3D‑Laser Chemical Vapor Deposition (3D‑LCVD) process, intended to deliver same-day crowns to local dentists, with near‑zero zirconia waste and without traditional sintering, hand staining, or porcelain layering. For a highly esthetic, more sustainable crown workflow, built to elevate dentist satisfaction and leave patients genuinely excited about their restorations. Ken brings 30+ years of advanced materials and microfabrication experience and 24 U.S. patents to this mission , along with hands‑on CAD/CAM crown production using both subtractive and additive manufacturing methods.

Have Questions?

Frequently Asked
Questions

When will your 3D printed zirconia crown be available?

By November 1, 2026, pending FDA approval to market.

Tell me more about your 3D printed zirconia crown.

3D‑printed, monolithic zirconia restorations with voxel level intrinsic shading designed to mimic surrounding natural dentition. 

How does the 3D printing process work?

Process is based on a 3D-laser chemical vapor deposition (3D-LCVD) technology,

What are the benefits over traditionally milled zirconia crowns?

3D‑printed, monolithic zirconia restorations with voxel level intrinsic shading designed to mimic surrounding natural dentition. Near‑zero zirconia waste and without traditional sintering, hand staining, or porcelain layering. For a highly esthetic, more sustainable crown workflow, built to elevate dentist satisfaction and leave patients genuinely excited about their restorations.

Do these 3D-LCVD printed zirconia crowns contain polymers?

The printed zirconia crowns are 100% ceramic without any residual polymer materials. Localized printing temperature at the laser spot is greater than 1700 degrees Celsius.