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Digital dentistry: an overview IN BRIEF

• CAD/CAM technology is widely available,

of recent developments for but little is known about it by the general

PRACTICE
dental practitioner.
• This article informs the practitioner

CAD/CAM generated restorations •


about recent developments in the field
of digital dentistry.
Information outlined in this article could
aid the cost-effective production of
dental prostheses.
F. Beuer,1 J. Schweiger2 and D. Edelhoff3

VERIFIABLE CPD PAPER

As in many other industries, production stages are increasingly becoming automated in dental technology. As the price
of dental laboratory work has become a major factor in treatment planning and therapy, automation could enable more
competitive production in high-wage areas like Western Europe and the USA. Advances in computer technology now en­
able cost-effective production of individual pieces. Dental restorations produced with computer assistance have become
more common in recent years. Most dental companies have access to CAD/CAM procedures, either in the dental practice,
the dental laboratory or in the form of production centres. The many benefits associated with CAD/CAM generated dental
restorations include: the access to new, almost defect-free, industrially prefabricated and controlled materials; an increase
in quality and reproducibility and also data storage commensurate with a standardised chain of production; an improve­
ment in precision and planning, as well as an increase in efficiency. As a result of continual developments in computer
hardware and software, new methods of production and new treatment concepts are to be expected, which will enable an
additional reduction in costs. Dentists, who will be confronted with these techniques in the future, require certain basic
knowledge if they are to benefit from these new procedures. This article gives an overview of CAD/CAM-technologies and
systems available for dentistry today.

1. DEFINITION
2. Software that processes data and, situations. This saves time and offers
The term ‘CAD/CAM’ in dental technol­ depending on the application, the patient indirectly fabricated resto­
ogy is currently used as a synonym for produces a data set for the product rations at one appointment. At present,
prostheses produced by ‘milling technol­ to be fabricated only the Cerec® System (Sirona) offers
ogy’. This is not entirely correct. CAD 3. A production technology that trans­ this possibility. Other producers also
is the abbreviation for ‘computer-aided forms the data set into the desired plan to introduce chairside CAD/CAM
design’ and CAM stands for ‘computer­ product. systems to the market. Since the Cerec®
aided manufacturing’. The term ‘CAD/ system functions with water-cooling, a
CAM’ does not provide any information 2. CAD/CAM PRODUCTION variety of materials can be processed,
on the method of fabrication. CONCEPTS IN DENTISTRY from glass-ceramic to high performance
All CAD/CAM systems consist of three Depending on the location of the com­ oxide ceramic. Clinical observations on
components: ponents of the CAD/CAM systems, in ceramic inlays are available over a period
1. A digitalisation tool/scanner that dentistry three different production of 21 years. Scientific literature reported
transforms geometry into digital concepts are available: success rates for CAD/CAM produced
data that can be processed by • chairside production inlays of 90% after ten years and 85%
the computer • laboratory production after 12 and 16 years.1-3 Historically, this
• centralised fabrication in a system was the first CAD/CAM system
production centre. in dentistry and is currently available in
its third product generation. One of the
1*
Assistant Professor, 2Head of Laboratory, 3Associate a) Chairside production benefits of this very mature system is the
Professor, Department of Prosthodontics, Ludwig-
Maximilians University, Munich, Germany All components of the CAD/CAM system software that has been supplemented by
*
Correspondence to: Dr Florian Beuer, Pacific Dental
Institute, 12750 SW 68th Avenue, Portland, Oregon,
are located in the dental surgery. Fabrica­ a very exact three-dimensional recon­
97223, USA tion of dental restorations can thus take struction of the occlusal surface.
Email: florian.beuer@med.uni-muenchen.de
place at chairside without a laboratory
Refereed Paper procedure. The digitalisation instrument b) Laboratory production
Accepted 28 March 2008
DOI: 10.1038/sj.bdj.2008.350
is an intra-oral camera, which replaces a This variant of production is the equiva­
© British Dental Journal 2008; 204: 505-511 conventional impression in most clinical lent to the traditional working sequence

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PRACTICE

between the dentist and the laboratory.


The dentist sends the impression to the
laboratory where a master cast is fab­
ricated first. The remaining CAD/CAM
production steps are carried out com­
pletely in the laboratory. With the assist­
ance of a scanner, three-dimensional
data are produced on the basis of the
master die. These data are processed by
means of dental design software. After
the CAD-process the data will be sent to
a special milling device that produces
the real geometry in the dental labora­
tory. Finally the exact fit of the frame­
work can be evaluated and, if necessary,
corrected on the basis of the master cast.
The ceramist carries out the veneering
of the frameworks in a powder layering Fig. 1 White light projector pattern during the scanning process by an optical scanner
or overpressing technique.4-7

c) Centralised production
The third option of computer-assisted
production of dental prostheses is cen­
tralised production in a milling centre.
In this variation, it is possible for ‘sat­
ellite scanners’ in the dental laboratory
to be connected with a production cen­
tre via the Internet. Data sets produced
in the dental laboratory are sent to the
production centre for the restorations to
be produced with a CAD/CAM device.
Finally, the production centre sends the
prosthesis to the responsible laboratory.
Thus, production steps 1 and 2 take place
in the dental laboratory, while the third
step takes place in the centre.5,8 As a
result, the configuration of the prosthe­ Fig. 2 Screen-shot of CAD-construction of 14 single crown copings
sis remains in the hands of the dental
technician. The benefit of outsourcing
CAM production is to be found in the
small investment requirement, since
only the digitalisation tool and soft­
ware have to be purchased, still having
access to a high quality production pro­
cess. In addition, this procedure results
in greater independence, since there is
no relation to a particular production
technology (such as, eg milling tech­
nology). It must, however, be noted that
presently almost all CAD/CAM systems
are only available as closed systems. In
other words, if one acquires a scanner
from one manufacturer, this implies, in
the case of a closed system, that there is
only access to that manufacturer’s pro­ Fig. 3 Different possibilities of the working axis: 3 spatial directions X, Y and Z (3 axis
cesses and line of products. In addition, milling devices); 3 spatial directions X, Y, Z and tension bridge A (4 axis milling devices); 3
spatial directions X, Y, Z, tension bridge A and milling spindle B (5 axis milling devices)
the dental laboratory loses the income

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PRACTICE

from producing the framework, since it • Everest Scan (KaVo, white light 3.3 Processing devices
is fabricated in the production centre. projections) The construction data produced with the
Many production centres also offer • es1 (etkon, laser beam). CAD software are converted into mill­
laboratories without a scanner the pos­ ing strips for the CAM-processing and
sibility of sending the master cast to the b) Mechanical scanner finally loaded into the milling device.
centre for scanning, designing and fab­ In this scanner variant, the master cast is Processing devices are distinguished by
rication. The additional veneering of the read mechanically line-by-line by means means of the number of milling axes:
frameworks for prosthetic restorations is of a ruby ball and the three-dimensional • 3-axis devices
carried out in the dental laboratory. structure measured. The Procera Scan­ • 4-axis devices
Recently, dentists have been offered ner from Nobel Biocare (Göteborg) is • 5-axis devices.
the possibility of sending the impres­ the only example for mechanical scan­
sion directly to the production centre ners in dentistry. This type of scanner is a) 3-axis milling devices
(biodentis). This application is presently distinguished by a high scanning accu­ This type of milling device has degrees
limited to ceramic inlays only. racy, whereby the diameter of the ruby of movement in the three spatial direc­
An additional simplification in CAD/ ball is set to the smallest grinder in the tions. Thus, the mill path points are
CAM production consists of intraoral milling system, with the result that all uniquely defined by the X -, Y -, and Z
data collection (optical impression). This data collected by the system can also – values (Fig. 3). The calculation invest­
means a digitalisation of what is now be milled.5,10 The drawbacks of this data ment is therefore minimal. A milling
only an ‘analogue’ step in the production measurement technique are to be seen in of subsections, axis divergences and
process. This could lead to additional the inordinately complicated mechanics, convergences, however, is not possible.
improvement in quality and cost reduc­ which make the apparatus very expen­ This demands a virtual blocking in such
tion. New software developments will sive with long processing times com­ areas. All 3-axis devices used in the
make it possible to directly judge the pared to optical systems. dental area can also turn the component
quality of the preparation intraorally, by 180° in the course of processing the
before data are finally sent to the dental 3.2 Design software inside and the outside. The advantages of
laboratory or production centre. Special software is provided by the these milling devices are short milling
manufacturers for the design of vari­ times and simplified control by means of
3. CAD/CAM COMPONENTS ous kinds of dental restorations. With the three axes. As a result, such mill­
3.1 Scanner such software, crown and fi xed partial ing devices are usually less costly than
dentures (FPD) frameworks can be con­ those with a higher number of axes.
Under the term ‘scanner’ one under­ structed on the one hand (Fig. 2); on Examples of 3-axis devices: inLab
stands, in the area of dentistry, data the other hand, some systems also offer (Sirona), Lava (3M ESPE), Cercon brain
collection tools that measure three­ the opportunity to design full anatomi­ (DeguDent).
dimensional jaw and tooth structures cal crowns, partial crowns, inlays, inlay
and transform them into digital data retained FPDs, as well as adhesive FPDs b) 4-axis milling devices
sets. Basically there are two different and telescopic primary crowns.11 The In addition to the three spatial axes, the
scanning possibilities: software of CAD/CAM systems presently tension bridge for the component can
• optical scanners available on the market is being continu­ also be turned infinitely variably (Fig.
• mechanical scanners. ously improved. The latest construction 3). As a result it is possible to adjust
possibilities are continuously available to bridge constructions with a large verti­
a) Optical scanners the user by means of updates. The data cal height displacement into the usual
The basis of this type of scanner is the of the construction can be stored in vari­ mould dimensions and thus save mate­
collection of three-dimensional struc­ ous data formats. The basis therefore is rial and milling time.
tures in a so-called ‘triangulation proce­ often standard transformation language Example: Zeno (Wieland-Imes).
dure’. Here, the source of light (eg laser) (STL) data.9 Many manufacturers, how­
and the receptor unit are in a definite ever, use their own data formats, spe­ c) 5-axis milling devices
angle in their relationship to one another. cific to that particular manufacturer, With a 5-axis milling device there is
Through this angle the computer can with the result that data of the construc­ also, in addition to the three spatial
calculate a three-dimensional data set tion programs are not compatible with dimensions and the rotatable tension
from the image on the receptor unit.9 each other. bridge (4th axis), the possibility of rotat­
Either white light projections or a laser The systems available on the market ing the milling spindle (5th axis) (Fig.
beam can serve as a source of illumina­ are differentiated mostly in their con­ 3). This enables the milling of complex
tion (Fig. 1). The following can be named struction software. While many systems geometries with subsections, as for
as examples of optical scanners on the emphasise an indication spectrum that example, lower jaw FPDs on converg­
dental market: is as broad as possible, other manufac­ ing abutment teeth (end molar tipped
• Lava Scan ST (3M ESPE, white light turers place emphasis on intuitive use towards the medial plane) (Fig. 4), or
projections) and user-friendliness. also crown and FPD substructures that,

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PRACTICE

as a result of anatomically reduced for­


mation, demonstrate converging areas
in the exterior of the frame.
Example in the Laboratory Area: Ever­
est Engine (KaVo).
Example in the Production Centre:
HSC Milling Device (etkon).
The quality of the restoration does not
necessarily increase with the number of
processing axes. The quality results much
more from the result of the digitalisation,
data processing and production process.

4. MILLING VARIANTS
a) Dry processing
Dry processing is applied mainly with Fig. 4 Pinned master cast of converging abutment teeth for a fixed partial denture in the
mandible. At least a 4 milling axis is required for the milling unit to fabricate a substructure
respect to zirconium oxide blanks with for this situation
a low degree of pre-sintering. This offers
several benefits:
• Minimal investment costs for the Table 1 Selection of resin materials for CAD/CAM systems
milling device
CAD/CAM
• No moisture absorption by the die Name Manufacturer
system
Description
ZrO2 mould, as a result of which there
Filler-free acrylic polymer for lost
are no initial drying times for the CAD-Waxx Vita inLab
wax technique
ZrO2 frame prior to sintering. Residue-free cauterisable resin for lost
Cercon base cast DeguDent Cercon
wax technique
Disadvantages: Residue-free cauterisable resin for lost
Everest C-Cast KaVo Everest
wax technique
• The lower degree of pre-sintering
results in higher shrinkage values for Fibre-free acrylic polymer with micro-filler
CAD-Temp Block Vita Cerec 3, inLab for long-term temporary full and partial
the frameworks. crowns and FPDs up to two pontics
Some manufacturers also offer the
Fibre reinforced polymer for long-term
option of milling resin material in a dry Everest C-Temp KaVo Everest temporary crowns and FPD frameworks,
milling process [Zeno 4030 (Wieland- requiring an additional veneering
Imes), Lava Form and Cercon brain]. Artegral
Merz Cerec 3, inLab
Semi individual blanks for anterior long-term
imCrown provisional single crowns
b) Wet milling
In this process the milling diamond or the respective production system. Some b) Resin materials
carbide cutter is protected by a spray of milling devices are specifically designed On the one hand, resin materials can be
cool liquid against overheating of the for the production ZrO2 frames, others used for the milling of lost wax frames for
milled material. This kind of process­ cover the complete palette of materials casting technology; on the other hand, it is
ing is necessary for all metals and glass from resins to glass ceramics and high possible to use resin materials directly as
ceramic material in order to avoid dam­ performance ceramics. The following crown and FPD frameworks for long-term
age through heat development. ‘Wet’ materials can normally be processed on provisional or for full anatomical long­
processing is recommended, if zirconium dental CAD/CAM devices: term temporary prostheses (Table 1). Pre­
oxide ceramic with a higher degree of fabricated semi-individual polymer blanks
pre-sintering is employed for the milling a) Metals (semi-finished) with a dentine enamel
process. A higher degree of pre-sintering At present, titanium, titanium alloys layer are provided by one manufacturer
results in a reduction of shrinkage factor and chrome cobalt alloys are processed (artegral imCrown, Merz Dental). The
and enables less sinter distortion. using dental milling devices. The mill­ exterior contour conforms to an anatomi­
Examples: Everest (KaVo), Zeno 8060 ing of precious metal alloys has been cally complete anterior tooth crown, while
(Wieland-Imes), inLab (Sirona). shown to be of no economic interest, due the internal aspect of the crown is milled
to the high metal attrition and the high out of the internal volume of the blank.
5. MATERIALS FOR material costs.
CAD/CAM PROCESSING Examples: coron (etkon: non-precious c) Silica based ceramics
The list of various materials for process­ metal alloy), Everest Bio T-Blank (KaVo, Grindable silica based ceramic blocks are
ing by CAD/CAM devices depends on pure titanium). offered by several CAD/CAM systems

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for the production of inlays, onlays,


veneers, partial crowns and full crowns
(fully anatomical, anatomically par­
tially reduced) (Table 2). In addition to
monochromatic blocks, various manu­
facturers now offer blanks with multi­
coloured layers [Vitablocs TriLuxe (Vita),
IPS Empress CAD Multi (IvoclarVi­
vadent)], for the purpose of full anatom­
ical crowns. Due to their higher stability
values, lithium disilicate ceramic blocks
are particularly important in this group;
they can be used for full anatomical ante­
rior and posterior crowns, for copings in
the anterior and posterior region and for
three-unit FPD frameworks in the ante­
rior region due to their high mechanical
stability of 360 MPa.12-15 Glass ceramics
are particularly well suited to chairside
application as a result of their trans­ Fig. 5 Enlarged zirconium oxide after the milling process before sintering to the
desired dimensions
lucent characteristics, similar to that
of natural tooth structure; they pro­
vide aesthetically pleasing results even e) Oxide high performance which, as a result of a transition to a
without veneering. As a result of their ceramics monoclinic phase can prevent the pro­
relatively high portion of glass, these At present, aluminum oxide and zir­ gression of cracks in the ceramic (Trans­
ceramics are, in contrast to oxide ceram­ conium oxide are offered as blocks for formation strengthening).24-27 Examples
ics, etchable with hydrofluoric acid and CAD/CAM technology. of Zirconium oxide blocks: Lava Frame
thus can be inserted very well using (3M ESPE), Cercon Smart Ceramics (Degu-
adhesive systems.16,17 Aluminum Oxide (Al2O3) Dent), Everest ZS und ZH (KaVo), inCoris
This oxide high performance ceramic Zr (Sirona), In-Ceram YZ (Vita), zerion
d) Infiltration ceramics is ground in a pre-sintered phase and is (etkon) and Zeno Zr (Wieland-Imes)
Grindable blocks of infi ltration ceramics then sintered at a temperature of 1520°C
are processed in porous, chalky condi­ in the sintering furnace. Aluminium Processing can take place in
tion and then infiltrated with lanthanum oxide is indicated in the case of crown different density stages
glass. All blanks for infi ltration ceram­ copings in the anterior and posterior area, a) Green stage processing
ics originate from the Vita In-Ceram primary crowns and three-unit anterior
system (Vita) and are offered in three FPD frameworks. The ground frames Green stage: blank without heat treat­
variations: can be individually stained in several ment, ie an object pressed from ceramic
• Vita In-Ceram Alumina (Al2O3): suit­ colours with Vita In-Ceram AL Coloring powder and binding agents.
able for crown copings in the anterior Liquid.5,21-23 Examples of grindable alu­ Since there was no pre-sintering, the
and posterior region, three-unit FPD minum oxide blocks: In-Ceram AL Block object is as soft as chalk. This permits
frameworks in the anterior region18 (Vita), inCoris Al (Sirona) available in an very easy processing, but results, due
• Vita In-Ceram Zirconia (70% Al2O3, ivory-like colour (Color F 0.7). to the low degree of stability, in great
30% ZrO2): suitable for crown copings problems in transport and application.
in the anterior and posterior region, Yttrium stabilised zirconium Processing is by means of carbide metal
three-unit FPD frameworks in the
oxide (ZrO2, Y-TZP) grinders without liquid cooling. The
anterior and posterior region. Thanks Zirconium dioxide is a high-performance green stage has an open porosity, and in
to its superior masking ability this oxide ceramic with excellent mechanical firing a 25% linear shrinkage is to be
ceramic is suitable for discoloured characteristics. Its high flexural strength expected. At present, zirconium oxide is
abutment teeth19,20 and fracture toughness compared with not processed as a green stage in any of
• VITA In-Ceram Spinell (MgAl2O4): other dental ceramics offer the possibil­ the CAD/CAM systems on the market.
has the highest translucency of all ity of using this material as framework
oxide ceramics and is thus recom­ material for crowns and FPDs, and, in b) White stage processing
mended for the production of highly appropriate indications, for individual White stage: pre-sintered blanks.
aesthetic anterior crown copings, in implant abutments. The addition of three As a result of the thermal pre-treatment
particular on vital abutment teeth molecules of Y2O3 results in a stabilising the organic compressing additives have
and in the case of young patients. tetragonal phase at room temperature, vanished and the blank has an adequate

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stability. As a result of pre-sintering, the


white body has already had shrinkage of Table 2 Selection of glass ceramic materials for CAD/CAM systems
approximately 5%. In the case of CAD/ CAD/CAM
Name Manufacturer Description
CAM production of objects from white system
bodies, the subsequent shrinkage of some Monochrome for inlays, onlays, veneers
Vitablocs Mark II Vita Cerec 3, inLab
20% (linear) must be taken into consid­ and full crowns
eration. Processing of white stage can be Monochrome for full anatomical crowns,
IPS e.max CAD Ivoclar Vivadent inLab, Everest
either with carbide metal grinders with­ copings and anterior three-unit FPDs
out water cooling or with diamond grind­ Vitablocs TriLuxe Vita Cerec 3, inLab
Polychromatic for inlays, onlays, veneers
ers with liquid cooling (Fig. 5).8,28 and full crowns
IPS Empress Polychromatic for inlays, onlays, veneers
Ivoclar Vivadent inLab
c) Processing in hot isostatic CAD Multi and full crowns
pressing condition
Some systems also process zirconium influenced dental-technical produc­
oxide in HIP (hot isostatic pressed) con­ tion procedures. If one ignores chair­
dition with diamond tools and water side prostheses, the significance of this
cooling. The advantages and disadvan­ technology for the dentist is not imme­
tages are as follows.15,29,30 diately clear. In recent years, CAD/CAM
Advantages: production has clearly expanded the
• No sinter shrinkage, as a result no palette of materials for dental prosthe­
sinter distortions ses by providing access to new ceramic
• No sinter furnace necessary materials with high dependability.15,28-31
• No additional time needed for The stability values of zirconium oxide
sintering procedure. ceramics permit, in many areas of indi­
cation, the use of this material as an
Disadvantages: alternative to metal frames for perma­
• Devices with high rigidity nent prostheses.30
and stability necessary The production of long-term temporary Fig. 6 Reverse bevel preparation making the
preparation border hardly detectable by the
• Longer milling times, resulting in prostheses has, as a result of the use of a CAD-software
lower utilisation of devices virtual wax up on the computer, become
• High wear of the cutters faster, more convenient and more pre­
• No coloured blanks available on the dictable. This method has already been on the surface of the prepared tooth as
market yet. implemented by computer-generated well as the ‘creation of troughs’ with a
long-term temporary restorations, since reverse bevel preparation margin can be
6. FUTURE TECHNOLOGIES it can be modified, by changing the inadequately recognised by many scan­
Generative production methods form, to the functional and aesthetic sat­ ners (Fig. 6). In addition, sharp incisor
isfaction of the patient during a clinical and occlusal edges are to be rounded.
Generative production methods are test phase. The production of the defi ni­ Sharp and thinly extending edges as
special CAD/CAM methods, which, in tive prosthesis should also be carried out well as 90° shoulders in a ceramic res­
contrast to grinding technology, do not by CAD/CAM technology and represents toration can result in a concentration of
work by subtracting, but rather by add­ merely a copying process of the tempo­ tension; in addition sharp edges cannot
ing material. In the dental area there are rary prosthesis into the defi nitive pros­ be milled exactly using rounded grind­
some areas of application for which this thesis by a different material. ers in the milling device. The diameter
technology is already applied. In some In spite of all the benefits of these of the smallest grinder is 1 mm in most
production centres, so-called ‘laser sin­ new methods, the dentist’s working systems, so structures smaller than 1 mm
tering devices’ are used to produce crown procedures will have to be adapted to cannot be milled precisely. The result is
and bridge frames from chrome cobalt the methods of CAD/CAM and milling an inaccurate fit.
alloys. Since the productivity of such technology. These include appropriate A 360 degree shoulder or cham­
devices is very high, dental restorations tooth preparations with the creation of fer preparation is considered to be
can be produced very cost-effectively. a continuous preparation margin, which the appropriate marginal preparation
Basically, geometries are conceivable is clearly recognisable to the scanner, geometries for CAD/CAM produced
with this technology that cannot be for example in the form of a chamfer all-ceramic restorations. In the case of
realised with grinding technology. preparation. Shoulderless preparations FPDs, the abutment teeth cannot show
and parallel walls should be avoided. On any divergence.
7. SIGNIFICANCE FOR THE DENTIST the basis of present knowledge, a tapered The precision of fit that can be achieved
In recent years, the use of CAD/CAM angle of between 4° to 10° is recom­ with the assistance of CAD/CAM sys­
technology has above all strongly mended.30 Subsections and irregularities tems is reported to be 10-50 µm in the

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marginal area.8,29,32-34 Thus, the demands 1. Otto T, De Nisco S. Computer-aided direct ceramic evaluation of posterior all-ceramic three-unit (In­
restorations: a 10- year prospective clinical study Ceram) FPDs. Int J Prosthodont 2001; 14: 379-384.
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