Available online 23 March 2023

A clinical and laboratory workflow for the digital design and fabrication of zirconia crowns and polyetheretherketone removable partial dentures for complete arch rehabilitation is described. The definitive crowns and polyetheretherketone framework can be delivered simultaneously because of the digital design and milling fabrication with retentive areas, guide planes, and rest seats in high-translucency zirconia crowns. The workflow helps simplify clinical and laboratory procedures and reduces patient visits and chairside time.

Make a polyvinyl siloxane impression (Elite HD; Zhermack) and pour in dental stone (Die-Stone; Kulzer GmbH).

Scan the cast with a laboratory scanner (DS300; Shining 3D) and export the data as a standard tessellation language (STL1) file.

Import the STL1 data into a CAD software program (exocad DentalCAD; exocad GmbH). Adjust the view to determine the insertion path of the future RPD and record it using the “Add custom view” tool (Fig. 2A). Under this view, add a cubic attachment to the cast and

For this complete arch rehabilitation, facial scanning procedures facilitated a facially driven diagnostic waxing, and dental and open-source software programs allowed the design of the zirconia crowns and RPD simultaneously. The resetting of the 3D position of the cast according to the ideal insertion path helped ensure the fit of the restoration during the design phase. Furthermore, subtractive manufacturing technologies simplified the fabrication of the zirconia crowns and RPD framework.

The

The present article describes a digital workflow using facial and laboratory scanners, dental and open-source software programs, and subtractive manufacturing technologies to facilitate complete arch simultaneous rehabilitation with machinable zirconia crowns and PEEK RPDs. Virtual diagnostic waxing with guide planes and rest seats and the framework of the RPD were designed and fabricated simultaneously. This workflow allows for a more efficient procedure, requiring less time than traditional

© 2023 by the Editorial Council for the Journal of Prosthetic Dentistry.