Methods for making a layered dental appliance. Some methods can include providing a solid structure (e.g., a die or a dental core, such as a fully sintered ceramic dental core) having a desired outer shape, and applying a first slurry to the solid structure to form a first free form layer on the solid structure. The method can further include solidifying the first free form layer on the solid structure, and machining the solidified first free form layer to a desired shape to form a first article comprising the solid structure and a first shaped layer. The method can further include applying, solidifying, and machining a second layer in a similar way to form a second article comprising the solid structure, the first shaped layer, and a second shaped layer. In some methods, the free form layers are not exposed to a high temperature prior to being machined.
