The split denture workflow has become a routine part of the work of many laboratories. It is used for both complete and partial restorations, including bridges with multiple pontics. The new DentalCAD 3.3 Chemnitz release makes the split denture process significantly simpler, and a further advantage is that its new features are integrated directly into DentalDB. This allows users to work with the familiar Bar Module and Implant Module.

The split denture feature is easy to use for software users of all experience levels, from beginners to experienced dental technicians. Thanks to the guided wizard workflow, the entire process is highly intuitive. The design process follows a backward-planning approach, beginning with the definitive restoration design. Users can then segment the design and generate the framework by applying the appropriate adaptation parameters to both components.

How it works

The case is first set up in DentalDB, including the parameters and options for the superstructure. Users will see the new option “Design bar?” in this early workflow stage (Fig. 1). By clicking “Yes, in Wizard”, they will automatically be guided into the split denture workflow. If users choose not to enable the workflow initially, they can still activate it later using the “Design bar?” option in expert mode.

When setting up the case in DentalDB, users can select the parameters for the bar design, such as the bar material. Other parameters, such as “Minimal thickness” or “Gap width of cement”, can be defined here and can be modified later in the workflow. All parameters and options set at this stage can be saved, allowing similar future cases to be managed more efficiently.

After designing the superstructure, including the teeth and gingiva, users proceed with bar design. The software offers a variety of options. New in the DentalCAD 3.3 Chemnitz release is the “Split” tab in the bar design step (Fig. 2). Users add and modify the split curve (Fig. 3), which defines where the structure will be separated. They can then choose from various bar adaptation options (Fig. 4) and adjust the parameters that influence the shape of and the spacing between the two components (Fig. 5). Once they click “Apply”, the software automatically separates the bar from the superstructure within seconds (Fig. 6). Users can then refine the bar and the adapted superstructure in the free-form step (Figs. 7 & 8).

Precise fit and passivity: the bar and its superstructure fit precisely together. DentalCAD 3.3 Chemnitz provides various parameters for dividing the structure, allowing users to make refined adjustments and improve passivity.

Strength and aesthetics combined: designing the bar as part of the split denture workflow helps to reinforce and stabilise the restoration while preserving the aesthetic advantages of zirconia and porcelain. Combining the superstructure with a bar adds stability and passive fit, helping to reduce stress on the zirconia and porcelain. Because users can control the parameters for both components within the same workflow, they can fine-tune the design as needed.

Reliable aesthetics with a wide range of materials: designing the bar as part of the split denture workflow helps to reinforce and stabilise the structure, without compromising aesthetics.

Flexible material options: the split denture workflow enables users to work with a wide range of materials, including resin composites, ceramic composites and zirconia. The same is true for the substructure, which can be made of metal, such as titanium, or other materials, such as PEEK in metal-free restorations.

Suitable for existing restorations

The DentalCAD split denture workflow can also be used to reinforce existing restorations. Users can import older restorations into the software and use the segmentation process to divide them into two parts (Fig. 9).

My personal tips

I encourage users to try the new split denture workflow in DentalCAD because it is very modern and cutting-edge. It offers many advantages: not only can it be applied to implant-supported full-arch restorations, but it also improves the stability of restorations by reinforcing them without compromising aesthetics.

An exocad wiki page on using the split denture workflow in the Bar Module explains every workflow step and parameter in detail. I highly recommend that users take a look. Users can access the page directly in the software by clicking the question mark icon in the wizard in the bar design step. Users can access many exocad resources to support their use of DentalCAD, including the exocad wiki and YouTube channel and personalised training.

More information about exocad's DentalCad 3.3 Chemnitz can be found here.