DLP (Digital Light Processing) chips form the heart of structured light projection systems in many intraoral scanners. When these microscopic mirror arrays malfunction, scan quality deteriorates in specific, recognizable patterns. Repair. Dental technicians analyze hundreds of scanner optical failures annually, revealing clear diagnostic indicators that differentiate DLP chip problems from other scanner issues.

This analysis draws from field repair data across multiple scanner brands, providing practical guidance for identifying projection system failures before they completely disable your digital impression workflow.

DLP Technology in Intraoral Scanners:

Structured Light Projection Fundamentals

Structured light intraoral scanners rely on a precisely controlled projection system to capture accurate digital impressions. At the core of this system is the DLP (Digital Light Processing) chip, which generates high-frequency light patterns projected onto tooth surfaces. These patterns deform over enamel, dentin, and soft tissue contours, allowing the scanner’s imaging sensors to calculate three-dimensional geometry in real time.

A DLP chip consists of hundreds of thousands to millions of microscopic mirrors, each measuring approximately 7–10 micrometers. These mirrors tilt rapidly—often thousands of times per second—to alternate between light and dark regions in the projected pattern. This rapid modulation is essential for achieving the spatial resolution required for crown margins, interproximal areas, and full-arch scans.

The DLP chip operates in synchronized coordination with:

High-intensity LED light sources
Projection lenses and focusing optics
Scanner cameras and image-processing software

Any disruption in this chain directly impacts scan accuracy, surface continuity, and digital impression reliability.

Alt Text: Structured light projection system inside an intraoral scanner showing DLP chip, mirror array, LED light source, and optical path used for digital impressions

Why the DLP Chip Is a Critical Failure Point

Despite its precision, the DLP chip is also one of the most mechanically stressed components in an intraoral scanner. Each mirror is mounted on a microscopic hinge connected to an electrode that controls its tilt angle. Over time, repeated high-speed movement introduces mechanical fatigue, particularly in high-volume clinical environments.

Key technical vulnerabilities include:

Hinge fatigue from millions of tilt cycles
Thermal stress caused by continuous LED illumination
Dust or particulate contamination is interfering with the mirror movement
Thermal expansion and contraction from repeated power-on cycles

Even minor mirror malfunction alters light projection symmetry, leading to localized scan defects that are often misinterpreted as calibration or software errors.

Common DLP Chip Failure Symptoms in Clinical Scanning:

Projection Pattern Defects and Image Artifacts:

DLP chip degradation produces distinct visual defects in structured light patterns. These defects translate directly into scan errors that cannot be corrected through technique adjustments alone.

Dead pixels occur when mirrors become permanently stuck in the “off” position, creating dark gaps in the projected pattern. While scanners may tolerate a small number of isolated dead pixels, clusters of failures result in persistent blind spots during scanning. Flickering artifacts indicate intermittent mirror response, often linked to thermal instability. These symptoms typically worsen as the scanner heats during extended use, leading to inconsistent scan quality across appointments.

Scan Quality Degradation Dentists Commonly Notice

When projection integrity declines, scan quality deteriorates in predictable ways. Dentists often report that scans appear “almost correct” but repeatedly fail in specific areas—regardless of scanning angle or operator skill.

Common clinical indicators include:

Consistent missing surface data in identical locations across scans
Grainy or noisy textures on otherwise smooth tooth surfaces
Repeated rescanning of the same tooth areas during full-arch workflows
Dark spots or lines are visible during calibration pattern projection.

Alt Text: Comparison of healthy and failing DLP chip projection patterns in an intraoral scanner showing dead pixels and brightness irregularities

Differentiating DLP Failures from Calibration Errors

One of the most costly mistakes practices make is assuming projection-related scan issues are purely calibration-related. While calibration errors typically produce variable and inconsistent inaccuracies, DLP chip failures generate repeatable, location-specific defects.

Key diagnostic distinctions:

Calibration issues → errors move or change between scans
DLP chip failures → errors appear in the same physical locations every time

A simple diagnostic approach involves scanning a uniform white target multiple times without changing the scanner position. Consistent dark or noisy zones strongly indicate DLP mirror failure rather than alignment or software faults.

Diagnostic Procedures for Suspected DLP Chip Failure

Visual Inspection of Structured Light Patterns

Direct observation of the projected pattern provides immediate insight into DLP chip health. When projected onto a flat, neutral surface, a healthy system displays uniform brightness and sharply defined patterns.

Recommended inspection steps:

Project calibration patterns at normal working distance
Observe brightness uniformity and pattern clarity
Identify any static, dark,k or bright defects
Repeat inspection after 10–15 minutes of scanner operation

Defects that increase with heat exposure strongly suggest thermally induced DLP degradation.

Calibration Results as Optical System Indicators

Most intraoral scanners generate spatial accuracy maps during calibration. DLP-related failures typically present as clustered error zones, not evenly distributed inaccuracies.

Calibration findings associated with DLP chip failure include:

Persistent error “hot spots” in fixed locations
Repeated calibration warnings despite successful completion
Declining accuracy values after extended scanner use

Comparing calibration results immediately after startup versus after continuous operation often reveals thermal sensitivity patterns linked to failing mirror arrays. Repair.Dental provides free diagnostic testing as part of its Intraoral Scanner Repair Service to accurately confirm DLP-related failures before repair.

Reference Scan Comparison Testing

Scanning a reference object with known geometry allows clinicians to isolate projection system faults. When repeated scans of a stationary object reveal identical data gaps or surface noise, the projection source becomes the primary suspect.

This reproducibility is a defining characteristic of DLP chip failure and provides strong justification for professional optical system evaluation rather than repeated recalibration attempts.

Repair.Dental Technician Insight

Across hundreds of intraoral scanner evaluations, our technicians observe that over two-thirds of scanners reported as “calibration failures” actually suffer from early-stage DLP chip degradation. The defining clue is consistency—defects appear in the same locations regardless of operator, patient, or scanning technique. When practices identify these symptoms early, DLP chip replacement restores scan accuracy before workflow disruption becomes critical.

Brand-Specific DLP Chip Failure Considerations:

Different intraoral scanner manufacturers integrate DLP technology with varying thermal control, mirror density, and calibration logic. These design choices directly influence failure frequency, repair complexity, and lifespan.

In scanners using high-resolution structured light projection, DLP chips are optimized for speed and detail, but higher mirror density also increases thermal and mechanical stress. Wireless scanners add another variable, as battery heat contributes to internal temperature rise, accelerating mirror hinge fatigue if cooling airflow is restricted.

From a repair standpoint, brand-specific calibration protocols are critical. Even a perfectly installed DLP chip will underperform if the manufacturer's calibration sequences are not followed precisely. This is why professional repair using OEM components and certified procedures is essential for restoring original scan accuracy.

Repair vs Replace: How Dentists Should Decide

When DLP chip failure is confirmed, the decision to repair or replace should be based on clinical reliability, cost efficiency, and workflow impact, not frustration.

When Repair Makes Clinical Sense

The scanner is under 5 years old
Scan accuracy was previously reliable
DLP chip is the primary failing component
Repair cost is under 25% of replacement cost
Practice wants minimal retraining or workflow change

In most cases, DLP chip replacement extends scanner life by 2–4 years, repairing the financially sound choice.

When Replacement May Be Better

Multiple optical components are degrading
Calibration system errors persist after repair
Scanner technology no longer meets clinical needs
Repeated downtime impacts patient scheduling

Repair.Dental offers free shipping both ways, free diagnostics, OEM DLP components, fast 3–5 day turnaround, and a 90-day repair warranty, allowing practices to restore scanner performance without financial risk.

Preventive Maintenance to Extend DLP Chip Life

DLP chip longevity is strongly influenced by the environment and handling.

Best practices include:

Maintain room temperature between 65–75°F
Keep humidity between 30–50%
Ensure cooling vents remain unobstructed
Avoid placing scanners near heat sources
Inspect projection patterns monthly
Follow manufacturer-recommended calibration intervals

Early detection allows planned repairs, avoiding emergency downtime.

Frequently Asked Questions:

Can individual DLP mirrors be repaired?
No. Individual mirrors cannot be repaired; the entire DLP chip must be replaced.

Is it safe to keep scanning with early DLP failure?
Short-term use is possible, but accuracy degrades progressively, and risks failed impressions.

How long does professional DLP chip repair take?
Typically, 3–5 business days with Repair.Dental, including calibration and testing.

Does DLP replacement restore original accuracy?
Yes, when OEM parts and manufacturer calibration protocols are used.

Are DLP failures usually software-related?
No. Most are hardware-based but are commonly misdiagnosed as calibration issues.

Is the repair covered by warranty?
Only if the scanner is within the manufacturer's warranty period. Repair. Dental provides a 90-day repair warranty.

Conclusion

DLP chip failures follow predictable patterns that directly affect scan accuracy and workflow efficiency. Recognizing consistent projection defects, localized data gaps, and temperature-related degradation allows dentists to diagnose issues early and avoid unnecessary recalibration cycles. In most cases, professional DLP chip replacement restores full functionality and extends scanner lifespan at a fraction of replacement cost.

For more professional dental equipment repair insights, please visit Repair. Dental or follow us on Facebook & Instagram.

Structured Light Projector DLP Chip Failure: Symptoms and Diagnosis in Intraoral Scanners