Clinical case
The future of dentistry is undoubtedly digital. As CAD/CAM replaces traditional workflows and becomes the standard in dentistry, digital solutions have become a necessity for every dental practice. However, the quality of the digital solutions still relies on the skills of the dentist, assistant, or technician. Digital dental technology reduces the risks and uncertainties caused by human factors and provides greater consistency, accuracy, and precision at every stage of the workflow. CAD dental software provides visual interfaces and views similar to traditional work processes, but in addition, certain steps can be automated, dental procedures improved, and work processes optimized. As a result, errors are easier to identify and correct. The following text introduces the digital fabrication of a fully anatomical crown and describes the process flow in detail..
Impression-taking/scanning
The use of manual impressions is being replaced by intraoral scanners, which means that the recording of individual patient anatomy now starts with digital production. Alternatively, dental laboratories can use optical desktop scanners to capture traditional impressions or plaster models. In the traditional process, the practice takes a physical impression of the patient, sends it to a dental laboratory, which then makes the necessary models, dentures, or other indications, and sends them back to the practice for treatment. Each intraoral scan reduces treatment time, decreases the amount of work, eliminates material costs, and removes the need to send impressions to a dental laboratory.
The digital capturing of dentition allows for immediate feedback and eliminates manual errors such as cavities, bubbles, or cracks, reducing the need for retakes. Using CAD software, the crown is designed, with highly visual interfaces offering functions such as virtual articulators familiar to dental technicians. This digital design simplifies treatments, improves precision, and enhances communication. The models can be exported for production, and if a new fabrication is required, the same digital design can be used without additional work, ensuring reproducibility.
CAM
After the crown has been designed using CAD software, it needs to be positioned in the material, known as a blank, from which it will be milled. For monolithic crowns, multi-layer blanks are used to closely simulate the tooth structure of a natural tooth, both visually and in terms of strength and other technical properties.
The CAM software, in this case Millbox from the company CIM system, calculates the optimal milling paths that are individually programmed for each material. Once the calculation is complete, the milling files are sent to the milling machine to create a physical crown from our digital design.
Milling DWX-52DCi
Milling machines can combine orders, operate unattended, and work overnight, enabling a laboratory to take advantage of an extra shift without incurring additional labor costs. The latest professional systems are now cost-effective, allowing dental laboratories of all sizes to benefit from them. In our case, we utilized the DWX-52DCI milling machine from DGSHAPE, a Roland DG Company (Japan).
The DWX-52DCi 5-axis dental milling unit allows for automated processing of a wide range of materials due to its 15-fold tool changer. The tool kits used by DGSHAPE ensure the milling tools have a long tool life of up to 180 hours.
The 6-fold blank changer also takes on the night shift, increasing productivity by turning night into day. The brush function ensures that the blanks are processed in a health-friendly manner.
After the milling process, the blanks are returned from the machine in the blank changer, free from dust.
In addition, this milling machine benefits from our specially designed high-performance spindle, which helps keep maintenance costs low.
Finish
After the milling machine has placed the blank in the changer, we can remove it with the crown freed from milling dust. The flood of new CAD/CAM-capable materials such as zirconium or lithium disilicate, which can only be used and processed via the digital process, not only ensures a portfolio expansion of the product range but also fully meets aesthetic requirements.
The flood of new CAD/CAM-capable materials such as zirconium or lithium disilicate, which can only be used and processed via the digital process, not only ensures a portfolio expansion of the product range but also fully meets aesthetic requirements.
Final review
Digital technologies offer significant benefits, including improved patient experience and comfort. Satisfied patients are more likely to return and refer others, contributing to the long-term success of a dental practice. Digital tools also streamline communication between the dentist and patients, as well as between the practice and the laboratory. As a result, digital dental technology ensures faster treatments, fewer appointments, and reduced manufacturing costs, leading to better clinical results.
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