Project Description

This project began as an exploration of 3D scanning, with the brief requiring the design of a product based on the exact dimensions of a scanned part of the body. I chose to design a series of custom-fitted grillz using a digital scan of my teeth.

The process began by creating a dental impression using dental putty to produce a negative mould of my teeth. Dental plaster was then poured into the mould to create an accurate positive cast, which was scanned using a high-resolution 3D scanner. The resulting STL file provided a precise digital model that formed the foundation for the design process.

Using the scan, I developed ten unique grillz concepts in CAD, exploring different forms and aesthetic styles while maintaining an exact fit to my teeth. From these concepts, three final designs were selected for production.

The chosen designs were resin 3D printed in a castable wax resin and manufactured using the lost-wax casting process in sterling silver. After casting, each piece was hand-finished through sanding and polishing to achieve a smooth, high-quality surface finish suitable for presentation.

The completed grillz were presented as the final outcome of the project, demonstrating the integration of digital scanning, CAD modelling, additive manufacturing, traditional casting techniques, and hand finishing into a fully realised wearable product.