Navigating the future of Swiss dental laboratories through advanced workflows, strategic partnerships, and expert support
ZM Solutions AG, headquartered in Bern, Switzerland, is a specialized provider committed to advancing digital dental technology. Founded in 2017, its comprehensive portfolio includes the sale of dental products tailored for digital workflows, as well as advanced 3D printing and precision milling of dentures and dental prostheses. Milling operations are performed using high-precision micro tools from OSG.
ZM Solutions AG offers 3D printing services and sells printers as part of a comprehensive end-to-end workflow solution. Photo courtesy of ZM Solutions AG.
Navigating Transformation in Swiss Dental Laboratories
Dental laboratories across Switzerland are undergoing significant transformation. Faced with emerging technologies, increased competition, and a shortage of skilled professionals, many dental labs are seeking ways to enhance profitability and ensure long-term viability. Industry analyses indicate that adopting service-oriented approaches and digital technologies is key to success. As digitalization progresses, personalized support and expert guidance are becoming increasingly critical, alongside traditional values such as quality, timeliness, flexibility, and reliability. This shift often involves evolving from a product-centric model to a service-oriented business with an expanded range of offerings.
Bridging the Gap for Smaller Laboratories
“The digitalization of daily operations is not only accelerating — it’s becoming more complex,” said Georg Orosz, managing director of ZM Solutions AG. “While software systems are becoming more user-friendly, they also encompass broader functionalities. Users require proper training to navigate these systems effectively.”
3D printing and milling of prostheses and dentures are central to ZM Solutions AG’s core business. Photo courtesy of ZM Solutions AG.
Hardware advancements further compound this complexity. Despite the core task of dental technicians — creating customized dentures — remaining unchanged, new challenges have emerged due to an aging population and evolving material technologies. For instance, zirconium oxide is now engineered to be softer from the basal area to the incisal edge, with aesthetics playing a more prominent role.
Milling is performed using micro tools from OSG. To achieve the high precision required for components such as cores or prostheses, re-milling is conducted in 2-micron increments. Photo courtesy of ZM Solutions AG.
These developments demand frequent updates to milling strategies and ongoing training. While large milling centers in Switzerland typically employ dedicated staff to manage these strategies, smaller laboratories often lag behind — not necessarily in equipment, but in access to expert support and strategic partnerships.
Delivering Immediate, Practical Solutions
ZM Solutions AG has positioned itself as a specialist in digital workflows for dental laboratories. Its services span the entire digital process — from data transfer and handling to design and production of dental workpieces.
“We also engage in design and manufacturing,” said Orosz, “but our primary focus is support.”
Client assistance at ZM Solutions AG is streamlined and responsive. All operations are managed online, and when a support ticket is submitted, a team member responds within 30 minutes — either with a solution or guidance on next steps. Most inquiries are resolved within half a day.
This rapid support, combined with software distribution, forms a major part of the company’s service offering. Additional services include milling, 3D printing, and the sale of materials such as zirconium oxide.
“We also sell 3D printers and provide complete workflow integration,” Orosz said.
Each printer undergoes extensive testing — up to four months — to ensure comprehensive post-sale support.
Efficient Networking and Tool Integration
Additive manufacturing is conducted in Bern using six 3D printers, while three machines are dedicated to milling. For milling operations, tool life and software compatibility are critical.
From left: Jens Schöngarth, team leader of OSG’s Dental & Medical Business Unit, Magnus Hoyer, head of the OSG Academy in Göppingen, and Georg Orosz, managing director of ZM Solutions AG, examine a milling cutter.
“It’s not just about placing the tool in the holder and starting the process,” Orosz said. “Our customers shouldn’t have to worry about these technicalities.”
To address these needs, ZM Solutions AG collaborates within a network of machine, software and tool manufacturers. A recent project in digital implantology, developed in partnership with OSG, illustrates this approach.
“We began with the design phase, followed by milling root posts,” Orosz said. “Precision is essential — over-milling can cause vibration in the pin. It must be accurate from the first step.”
OSG provided precision tooling and teamed up with a CAM manufacturer to refine the machining strategy.
“Once the strategy was finalized, we tested it and presented it to ZM Solutions AG alongside the CAM partner,” said Jens Schöngarth, team leader of OSG’s Dental & Medical Business Unit.
Precision Tools for Demanding Applications
The success of this collaboration is largely attributed to the precision of OSG’s tools.
“Our milling cutters are ground to an exceptionally tight tolerance of ±3 to 5 µm,” said Schöngarth. “This ensures high contour accuracy, which is vital for producing precise fits.”
For example, telescopic prostheses require the secondary component to fit perfectly onto the primary crown. ZM Solutions AG pre-mills these workpieces and then performs re-milling in 2-µm increments to achieve the required fit.
“The tools perform exceptionally well,” said Orosz.
Magnus Hoyer, head of the OSG Academy in Göppingen, highlighted another key feature.
“OSG continues to rely on 2-flute, coated tools for machining PMMA,” Hoyer said. “Our highly polished DLC coating is extremely thin, maintaining sharp edges while ensuring long tool life.”
He also noted the development of a single-flute geometry for a major materials specialist in Germany, designed to prevent clogging during high-speed plastic milling — a common issue due to heat buildup and melting.
OSG’s WXS-CRE milling cutters for roughing and WXL-LN-EBD for semi-finishing and finishing are already well-established in ZM Solutions AG’s production processes.
To address varying radial forces during milling, OSG has engineered micro milling cutters with a teardrop shape and a large taper, eliminating flat contact points on the outer diameter. Additionally, for larger micro tools, OSG adjusts the rake angle from the center to the outer diameter to reduce cutting pressure — a technique borrowed from mold and tool making, now successfully applied in dental technology.
Precision, Durability, Performance: Key Requirements in Dental Tooling
“The most critical requirements for tools in the dental industry are precision, durability and performance,” said Hoyer.
In addition to tool quality, collaboration with specialists in process design, programming and machining strategy plays a vital role in achieving optimal results across various materials.
For example, ZM Solutions AG utilizes 5-flute solid carbide torus cutters from OSG’s WXS-CRE series for roughing titanium, capable of machining materials up to 65 HRC.
“We use these tools for roughing root pins, where close-contour milling provides significant advantages,” said Orosz. “They also deliver excellent surface quality in titanium, which is essential for dental applications, particularly for subsequent processing.”
These cutters are also well-suited for manufacturing retainers — orthodontic devices designed to maintain tooth alignment post-treatment.
“They’re milled as very thin square wires, and we’ve experienced no stability issues. The fit accuracy is also outstanding,” Orosz added.
For semi-finishing and finishing in titanium, ZM Solutions AG employs OSG’s WXL-LN-EBD ball nose tools. These 2-flute cutters feature a long neck specification, complemented by OSG’s proprietary WXL coating, making them ideal for titanium machining.
Driving Dental Innovation: Pioneer Next-Gen Milling for Zirconium Oxide and PMMA
Orosz is currently in the testing phase for processing zirconium oxide and PMMA.
“I’ve already developed several designs and evaluated various milling strategies,” he said.
For zirconium oxide, diamond-coated solid carbide milling cutters from OSG’s DG-LN-EBD series were employed.
“The surface quality post-milling was so exceptional that it appeared polished even before sintering,” Orosz said.
Next in line is PMMA, which will soon be processed using specialized OSG LN-EBD tools.
“I’m very optimistic about the results,” he added.
Orosz acknowledged the complexity of digitalization in dental laboratories and welcomed support.
Partners for the right tools and machining strategies for every application. From left, Magnus Hoyer, head of the OSG Academy in Göppingen, Jens Schöngarth, team leader of OSG’s Dental & Medical Business Unit, and Georg Orosz, managing director of ZM Solutions AG pose for a photo at the ZM Solution AG headquarters in Bern, Switzerland.
“With OSG, we have a partner that consolidates resources and expertise in tooling, enabling us to deliver targeted information and effective solutions directly to our customers,” he said.
For more information on OSG’s dental solutions, OSG GmbH and ZM Solutions AG
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