Overview
Fabricating a passively fitting dental framework requires precision at every stage: accurate dental master cast, appropriate material selection, optimized design, and controlled manufacturing. Even with perfectly positioned analogs, design decisions and fabrication technique affect whether the final dental framework seats without stress.
What You'll Need
- Verified dental master cast with accurate dental analog positions
- CAD/CAM dental design software with implant library
- Appropriate dental framework material (titanium, chrome-cobalt, dental zirconia)
- Precision milling equipment or casting setup
- Measurement and inspection tools
- Try-in components for clinical verification
Step-by-Step
Confirm Cast Verification
Before beginning design, verify that the dental master cast has passed accuracy testing using the clinical dental verification jig.
Select dental framework Material
Choose material based on clinical requirements. Milled titanium offers excellent accuracy and biocompatibility. dental zirconia provides aesthetics. Chrome-cobalt remains economical.
Scan the dental master cast
Digitize the dental master cast using a high-accuracy dental laboratory scanner. Capture dental analog positions, soft tissue contours, and reference landmarks.
Import into dental design software
Load scan data into dental CAD software with implant-specific libraries. Verify that dental analog positions import correctly.
Design with Passive Fit Priority
Design the dental framework to minimize stress concentration and optimize screw access. Consider cantilever length limitations and cross-sectional dimensions.
Account for Material Properties
Each material behaves differently during processing. Titanium mills accurately. dental zirconia shrinks during sintering. Apply appropriate compensation factors.
Plan for Try-In
Design the dental framework to allow try-in evaluation before final finishing. A bare dental framework can be adjusted more easily.
Execute Manufacturing
Mill, print, or cast the dental framework according to material requirements. Monitor manufacturing parameters and inspect for defects.
laboratory Sheffield Testing
Before clinical delivery, test the dental framework on the dental master cast using Sheffield protocol. The dental framework should fit the verified cast passively.
Prepare for Clinical Try-In
Clean and sterilize the dental framework. Include appropriate try-in screws. Document dental laboratory verification results.
Tips & Best Practices
- Use design libraries specific to your dental implant systems for accurate virtual positioning
- Build conservative safety margins into cantilever lengths and connector dimensions
- Consider dental framework segmentation for very long spans
- Maintain detailed documentation of design decisions
Common Mistakes to Avoid
Designing on unverified casts
Even perfect design and manufacturing cannot overcome inaccurate dental analog positions.
Ignoring material shrinkage
zirconia sintering shrinkage must be compensated in design. Failure to account produces undersized dental frameworks.
Excessive cantilever length
Long cantilevers amplify any positional error and stress implants. Follow evidence-based length limits.