Digital Dental Workflows: From Scan to Design to Fabrication

The evolution of digital dentistry has completely transformed how dental professionals and laboratories manage restorative and orthodontic cases. From the initial scan to the final fabrication, the digital dental workflow ensures greater precision, faster turnaround times, and improved patient satisfaction. In this guide, we’ll explore how each step in the process — scanning, designing, and fabrication — integrates into a seamless digital ecosystem that defines modern dental care.

1. What Is a Digital Dental Workflow?

A digital dental workflow refers to the end-to-end process of creating dental restorations and appliances using digital tools and software. Instead of relying on traditional impressions and manual design, digital workflows utilize 3D scanning, CAD/CAM software, and additive or subtractive manufacturing technologies to produce accurate and customized restorations.

This workflow typically includes three major stages:

• Digital Scanning – Capturing a 3D model of the patient’s oral anatomy using an intraoral or desktop scanner.
• CAD Design – Designing crowns, bridges, aligners, or implants using powerful dental CAD software.
• Fabrication – Producing the final restoration via 3D printing or milling systems.

2. Step 1: The Scanning Phase

The foundation of every successful digital case begins with accurate scanning. Whether performed in a clinic or laboratory, a high-quality 3D scan captures every contour of the patient’s dentition.

Types of Dental Scanners:

• Intraoral Scanners: Devices like 3Shape TRIOS, iTero, and Medit i700 capture direct digital impressions inside the patient’s mouth.
• Desktop Scanners: Used in dental labs to scan physical models or impressions. Examples include 3Shape E Series and DOF Freedom HD.

Digital scanning eliminates the need for messy impression materials, reduces errors, and enables instant data sharing with dental technicians through cloud platforms such as 3Shape Unite or Dental Wings Open System (DWOS).

Key Benefits of Digital Scanning:

• Highly accurate digital impressions
• Enhanced patient comfort
• Faster turnaround and improved communication
• Immediate visualization and verification of data

3. Step 2: CAD Design – The Digital Blueprint

After scanning, the digital data is imported into CAD (Computer-Aided Design) software for restoration design. This stage allows dental technicians and clinicians to model, modify, and optimize restorations virtually.

Popular CAD platforms in digital dentistry include:

• 3Shape Dental System – Advanced features for crowns, bridges, and implant cases with AI-driven automation.
• exocad DentalCAD – Known for its flexibility and open architecture, suitable for labs of any size.
• DWOS (Dental Wings Open System) – Integrated solution offering collaboration between labs and clinics.
• Planmeca Romexis – A comprehensive ecosystem covering design, imaging, and production.

Each platform offers specialized modules such as implant planning, orthodontic aligner design, and full-denture creation. These modules help technicians streamline workflows and maintain accuracy across multiple restoration types.

Essential Features to Look For:

• Automatic margin line detection and tooth anatomy suggestions
• AI-driven design tools for time efficiency
• Open file formats (STL, PLY, OBJ) for seamless integration
• Cloud-based case management for collaboration

The CAD design stage is where creativity meets technology — every digital restoration is crafted with precision, ready for manufacturing.

4. Step 3: CAM and Fabrication

Once the design is finalized, it moves to the CAM (Computer-Aided Manufacturing) stage, where it’s transformed into a physical restoration. There are two main fabrication technologies used in dental labs:

1. Milling (Subtractive Manufacturing)

In milling, the restoration is carved from a solid block of ceramic, zirconia, or resin using high-precision mills such as Roland DWX or imes-icore systems.

2. 3D Printing (Additive Manufacturing)

3D printing builds the restoration layer by layer, enabling the production of dental models, aligners, and temporary crowns. Leading dental printers include Formlabs Form 4B and Asiga MAX UV.

Advantages of Digital Fabrication:

• Faster production time
• Less material waste
• Repeatable precision
• Cost-effective scalability

The combination of CAD/CAM and 3D printing allows dental labs to deliver custom restorations within hours rather than days.

5. Integrating Digital Workflow in Your Lab

Implementing a digital workflow requires more than just new equipment — it involves optimizing your entire process. Start with compatible hardware and software that communicate seamlessly. For example, a lab using 3Shape scanners and exocad CAD software can easily integrate with open CAM systems for printing and milling.

Additionally, ensure proper training and support for your team. Many software vendors provide online academies and certification programs to help labs maximize performance and accuracy.

6. Benefits of a Fully Digital Workflow

• Improved Accuracy: Eliminates distortions caused by traditional impressions.
• Speed: Faster turnaround from design to delivery.
• Collaboration: Cloud-based systems enable real-time case sharing between dentists and labs.
• Customization: Perfect fit and aesthetics for each patient.
• Data Storage: Easy case management and retrieval for future reference.

Digital workflows are also environmentally friendly, reducing the use of plaster, silicone, and disposable materials. This contributes to more sustainable dental production practices.

7. Challenges and Considerations

While digital workflows offer numerous advantages, transitioning from analog processes may involve challenges:

• High initial investment in hardware and software
• Training requirements for staff
• File compatibility between different systems
• Regular software updates and maintenance

To overcome these, choose open-architecture solutions, invest in proper onboarding, and maintain regular technical support agreements.

8. The Future of Digital Dentistry

The next generation of digital dental workflows will be driven by artificial intelligence, cloud-based collaboration, and full automation. AI algorithms already assist in automatic tooth setup, implant placement, and occlusal adjustment, significantly reducing design time.

Moreover, remote case sharing and cloud storage will make dental labs globally connected — allowing seamless collaboration between clinicians, technicians, and manufacturers anywhere in the world.

Conclusion

The transition to a digital dental workflow is no longer optional — it’s a necessity for modern dental laboratories and clinics aiming for precision, efficiency, and scalability. From scanning to CAD design to fabrication, every step enhances productivity and patient satisfaction. Investing in open, integrated systems ensures your lab stays ahead of industry trends and technological advancements in digital dentistry.