Is digital transformation the future of dental laboratories?
The short answer is “Yes”. Digital transformation is already changing the way dental technicians work. From scanning and 3D modeling to automated milling and 3D printing of dentures, crowns, bridges and orthodontic appliances. But the answer is not so clear-cut. Some dental laboratories prefer the “traditional way”. That is, manual work, with no or minimal use of CAD / CAM technologies, 3D printers and digital scans. Such laboratories use traditional techniques such as wax modeling, castings, hand-layering of ceramics, metal-ceramics, traditional splints and prostheses.
“The Modern”
Both methods have their advantages and disadvantages. There is constant talk of “modernization and innovation”. But in fact traditional methods cannot be simply overstretched. CAD / CAM technologies are an expensive investment, more accessible to large laboratories. One of the biggest advantages is higher precision. Machines reduce the “human error” and produce faster.In the long run, digital processes save materials and time. This leads to lower costs and a gradual return on investment. In a presentation at the IDS dental exhibition Cologne 2025 presented, however, that there is no 100% digital protocol at work, because if there is a human touch, the process is no longer 100% digital. But let’s look at the steps it involves.
Digital protocol at work
If we imagine a complete digital line, the steps could look like this:
- First, dental technicians receive the data. The clinic sends an intraoral scan file (for example, from 3 Shape TRIOS , iTero or Medit ) instead of an analog impression. The data arrives as an STL , PLY or OBJ file.
- Next, specialists import the files and case. They create a local folder with the case files with the patient name/ID ,date, case type. Or labs can use a management software such as AMOSYS .
- Stage 3: These are the model analysis and preparation: checking the quality of the scan, margins, occlusion, contacts, checking for holes or distortion in the scan. If necessary, dental technicians clea and align the models.
- The fourth step is digital design ( CAD ). Some software that dental technicians can use for this are: Exocad, 3 Shape Dental System, Dental Wings. They can design crowns, bridges, veneers, implant abutments , digital smile design ( Digital Smile Design ) in aesthetic cases, etc. Once the design is approved, step 5 follows.
- Fifth step: fabrication (CAM): For solid structures (zirconium, metal) a CNC milling machine (for example Ivoclar, PrograMill or Roland), and for temporary structures, models or splints: a 3D printer (e.g. Asiga ,Formlabs, Stratasys).
- Stage 6: Manufacturing: If the lab has a CNC/ 3D printer, it can manufacture the structure itself without relying on external fabrication. In case of in-house manufacturing, process monitoring is recommended. In this way specialists can avoid problems with materials and machinery.
- Stage 7: Shaping and Aesthetics: Dental technicians process further models and frameworks. This includes removal of support elements, polishing, staining, glazing, sintering for zirconia (firing in a furnace at ~1450°C), before glazing. At this stage, the hand of experienced dental technicians may be involved to ensure aesthetics and fine-tuning.
- Step 8: Quality control – reviews the accuracy of workmanship, contact points, occlusion, review of color match, surface texture.
- 9: Shipping and delivery : carefully package the product, provide instructions to the dental practice (e.g. recommended cement), update the case status in the management software (e.g. in AMOSYS ), and notify the practice that the case is ready or shipped.
An example of a complete digital workflow
And the “traditional”
The traditional way of working is more typical for small dental laboratories. But it is not only the expensive investment in CAD / CAM that is the reason for abandoning this way of working. Although for simpler products, new technologies reduce the chance of human error, it turns out that technologies cannot completely replace master dental technicians. For certain types of work – such as fine ceramics or complex composite structures – manual labor is still superior to machine production, which makes classical production sought after by many clinics and dentists. A large number of master dental technicians with many years of experience also prefer classical methods. In cases of orders for unique, close to natural-looking prostheses, where the “human” element of manual production is required, specialists also prefer the classical method.