Purpose: This report introduces a fully digital workflow for the fabrication of implant superstructures in an esthetic zone using an intraoral scanner (IOS), computer-aided design/computer-aided manufacturing (CAD/CAM) technology, and monolithic multilayer zirconia.
Methods: Digital impressions of scan bodies and occlusal registration were made in the esthetic zone using an IOS. The provisional restoration in the oral cavity was scanned, and the provisional restoration with an optimized surface morphology of the subgingival contour was scanned outside the oral cavity. These morphological data were integrated into the CAD software to generate a digital cast. The morphology of the final superstructure was generated based on morphological data of the provisional restoration. The final superstructure was fabricated from monolithic multilayer zirconia using a CAM machine, sintered, colored with a stain material, and subsequently bonded to a titanium base using resin cement.
Conclusions: The superstructure was successfully fabricated using a model-less, fully digital workflow, and delivered to the patient. No clinical complications were reported. Thus, within the limitations of this report, the novel developed superstructure fabrication techniques can change the clinical and laboratory workflows from analog to digital in the esthetic zone.
Keywords: CAD/CAM; Digital impression; Fully digital workflow; Implant superstructure; Multilayer zirconia.