If you are running a dental office, you may have patients who require custom dental appliances. From smile shapers to crowns, a variety of appliances are needed to treat dental issues. Dental labs provide a controlled environment where technicians craft appliances to meet each patient’s unique clinical needs. Here are the steps involved in creating custom dental appliances:
Receiving the Case
The process begins when the lab receives the case from the dentist. The case will be presented in either physical or digital form. A specific prescription will also be included, containing the appliance type, material choices, and shades. Laboratory technicians carefully evaluate the impressions to make sure they have the necessary level of detail to create an accurate product.
If they identify irregularities or incomplete data, the laboratory contacts the dental office to address the issue before moving forward. Dental labs rely on accurate case information to create appliances to the dentist’s specifications. Effective communication at this stage prevents subsequent alterations and allows the fabrication process to proceed uninterrupted.
Starting Digital Designs
After the incoming case materials are verified, the lab creates a working model of the patient’s mouth. In the case of physical impressions, technicians pour dental stone to create an accurate replica of the oral anatomy. This replica serves as a guide for designing and fabricating stable appliances. For digital submissions, the lab utilizes specialized CAD/CAM software to create a virtual model that replicates the same level of anatomical detail. The model is used as the reference point for all production decisions. Laboratory technicians evaluate elements like bite relationship, surface characterization, and arch configuration. This precision allows for a precise end product. Both physical and digital modeling require the same technical skills and attention to detail.
Selecting the Materials
With the model complete, the lab works closely with the dentist to select the appropriate materials. Full dentures typically use acrylic resin bases with acrylic or porcelain teeth, whereas partial dentures often feature cast metal frameworks for added durability. Crowns and bridges may contain ceramics, metal-ceramic, or high-strength alloys, depending on the dentist’s requirements.
The functional purpose and desired aesthetic result of the appliance influence the material choice. The laboratory’s knowledge of material characteristics enables technicians to make informed choices that provide strength, durability, and a natural appearance. Technicians can discuss the pros and cons of certain materials. They may recommend using zirconia for posterior restorations or e.max for anterior work.
According to Dentist Marlborough, the selection process is a collaborative effort between the dental lab and the dentist. The dentist provides the clinical guidance and patient-specific needs, while the laboratory contributes its expertise on material science and fabrication techniques. This partnership ensures the final restoration is not only functionally sound and aesthetically pleasing but also meets the patient’s specific requirements for strength and biocompatibility, resulting in a successful outcome.
Fabricating the Appliance
For removal appliances, such as partials and dentures, technicians seat the teeth in wax to verify occlusion and alignment against the model. They then process the base in acrylic resin, cure it, and then reline it to replicate the gum contour. For fixed appliances such as crowns and bridges, technicians will mill the restoration from ceramic or cast it from a wax pattern before adding ceramic layers for a natural finish.
Dental laboratory technicians employ traditional techniques with modern tools to achieve accuracy in every appliance. They pay careful attention to occlusion, contact points, and contours. When matching shades for anterior teeth, technicians may use a combination of shades to achieve the most aesthetically pleasing result.
Supporting Quality Control
After the technicians have finished fabricating the appliance, it enters the finishing stage. Technicians shave away unnecessary material, buff out surfaces, and refine contours to achieve a smooth, natural appearance. In esthetic appliances, shade adjustments are made to replicate the patient’s existing look. Visual accuracy here is beneficial for restorations in the anterior parts of the mouth. They then perform the necessary quality control checks. Technicians test appliances against the model to verify a proper bite and fit. They also examine the surfaces for defects or inconsistencies. Appliances that meet the laboratory’s technical specifications are released for delivery to the dental clinic.
Work With Reputable Dental Labs Today
Working with expert dental labs enables you to deliver quality patient appliances that are specifically tailored to meet their clinical requirements. Experienced technicians working with innovative tools create precise, long-lasting, and comfortable dental appliances. CAD/CAM equipment enables easy modeling and designing, allowing dentists to achieve quick results during emergencies or other urgent situations. Learn how to get started working with a dental lab today by finding a reliable provider near you.