Digital Dentistry Workflow


The digital dentistry workflow transforms traditional, physical impressions and plaster models into a precise, entirely digital manufacturing ecosystem. Here is how this 5-step workflow operates in real-life dental practices and commercial dental laboratories:


Step 1: Digital Data Capture & Intake

  • In Practice: The dentist uses an intraoral scanner (a small digital wand) to capture a 3D digital impression of the patient's teeth and gums in minutes, eliminating messy physical impression putty. Alternatively, physical impressions are taken and sent to a lab where a desktop scanner digitizes them.


  • In Lab: The technician receives these files via a secure portal (along with the digital prescription) as STL, PLY, or OBJ files and checks them for margin clarity and bite accuracy.


Step 2: CAD Design & Slicing

  • In Practice: Typically handled by the lab, though some high-tech clinics design in-house using chairside CAD software.


  • In Lab: Technicians use specialized Dental CAD software (such as exocad or 3Shape) to digitally design the restoration, crown, surgical guide, or orthodontic appliance on the computer screen. Once approved, the design file is sent to slicing software, which cuts the digital object into ultra-thin horizontal layers and adds virtual support structures.


Step 3: 3D Printing (Additive Manufacturing)

  • In Practice/Lab: The sliced file is sent to a resin 3D printer (using LCD or DLP technology). The printer builds the dental appliance layer-by-layer out of specialized, biocompatible liquid photopolymer resins tailored for specific medical devices (e.g., rigid resins for models, flexible resins for night guards).


Step 4: Post-Processing

  • In Practice/Lab: Freshly printed parts are coated in uncured liquid resin and must be cleaned.


  • Washing: Parts are submerged in an Isopropyl Alcohol (IPA) wash station for a few minutes to strip away excess resin.

  • Post-Curing: Once dry, the parts are placed into a UV light-curing chamber. This step locks in the final mechanical strength, stability, and medical-grade biocompatibility required for safe oral use.


Step 5: Finishing & Quality Control

  • In Practice/Lab: Support structures are clipped away, and surfaces are ground, smoothed, or polished (and sometimes stained/glazed for aesthetics).


  • Final Delivery: The finished product is quality-checked for dimensional accuracy and fit against the digital model before being shipped to the clinic for patient seating.