Some cases require multiple skills working together. Identifying the most effective strategy and helping every team member contribute at their best often makes the difference between uncertainty and predictable results.

This case study originates from a collaboration with an implant-focused clinic that regularly managed complex All-on-4 and All-on-6 rehabilitations.

The initial request was an I-Bar solution with zirconia aesthetics. The reference for the project was a tooth setup created by the in-house laboratory and already validated and approved by both the clinician and the patient.

                                                                           CAD image of the validated and approved scanned setup

While the in-house laboratory was responsible for the setup and the final characterization of the restoration, the CAD design and production of the framework and zirconia components were outsourced to external laboratories.

Despite working with different suppliers over the years, the clinic continued to experience unsatisfactory results.

The issue was not a lack of technology.

The issue was not the digital tools.

The issue was that the CAD designs and CAM strategies developed by the external laboratories were often unable to faithfully transfer the information validated during the clinical phase.

Morphology, tooth position, articulation and details approved in the original setup were not consistently reproduced in the final restoration.

As a result, the final outcome often failed to meet the expectations originally shared between the clinician, the patient and the laboratory.

A second challenge also had to be considered.

The in-house laboratory was responsible for the final stages of production, including zirconia characterization, pink aesthetics and final prosthetic finishing.

However, the requested I-Bar solution required specific technical skills and production protocols that were not fully aligned with the operational experience of the team responsible for these final stages.

After a complete analysis of the workflow, I proposed a Toronto Thimble solution.

Digital Transfer Verification

The objective was not simply to improve the aesthetic outcome of the rehabilitation.

The objective was to identify a workflow capable of accurately transferring validated information, simplifying critical production stages and better matching the operational capabilities of the team involved.

The result was not merely a different restoration.

The result was a more predictable process, greater control over the workflow and a final outcome more closely aligned with the clinical, technical and aesthetic objectives of the case.

Comparison and verification of morphology, tooth position and validated clinical information before the final production of a Toronto Thimble restoration.

Final Consideration