Patient presentation

A female patient presented with dissatisfaction with her existing composite veneers in the maxillary anterior region. The restorations showed wear, marginal irregularities, chipping and discoloration, adversely affecting her smile and self-confidence (Figs. 1a–g).

The patient requested a natural-looking, durable and aesthetically pleasing solution, preferably without significant tooth reduction. During the initial consultation, she emphasised the importance of preserving her natural tooth structure and completing the treatment in as few visits as possible owing to professional commitments.

Clinical examination and diagnosis

A comprehensive diagnostic assessment was conducted. This included intra-oral and extra-oral photographic documentation, clinical examination of the hard and soft tissue, periodontal evaluation, occlusal analysis and assessment of the existing restorations.

The existing composite veneers exhibited marginal discoloration, surface roughness, chipping and inadequate anatomical form. No secondary caries or pulpal pathology was detected. The periodontal tissue was healthy, probing depths were normal and there were no signs of inflammation.

Occlusal analysis confirmed stable intercuspation and the absence of premature contacts. Temporomandibular joint function was considered to be within normal limits, and the patient reported no history of pain or dysfunction. Based on these findings, the case was considered suitable for conservative veneer replacement using a digital workflow.

Treatment planning

After the diagnostic phase, a detailed treatment plan was formulated. The main objectives in replacing the old composite veneers were to preserve as much enamel as possible, improve aesthetics and surface texture, maintain functional occlusion and complete the treatment in a single visit.

Several restorative options were discussed with the patient, including conventional laboratory-fabricated ceramic veneers and chairside digital restorations. After reviewing the advantages, limitations, treatment duration and costs, the patient opted for a chairside digital approach using 3D printing. Informed consent was obtained, and expectations regarding shade, shape and the final outcome were discussed in detail.

Tooth preparation

The existing composite veneers were carefully removed using fine-grit diamond burs under magnification. Minimal preparation was performed in accordance with enamel-preserving principles. The preparation design included light facial reduction of 0.3–0.5 mm, rounded line angles and light chamfer finishing lines. The preparation was limited primarily to the previously restored areas. The aim was to maximise the enamel bonding surface and thereby support long-term adhesion and clinical longevity.

Digital impression and smile design

After tooth preparation, the teeth were cleaned and isolated. A digital impression was acquired using an intra-oral scanner, producing high-resolution digital models and eliminating the need for conventional impression materials. The digital files were transferred to smile design software, where planning was performed. Tooth proportions, incisal edge position, smile line, midline alignment, buccal corridor, gingival symmetry and facial harmony were evaluated and optimised.

A digital smile design and virtual restorative design were generated to simulate the proposed restorations (Figs. 2a & b). The virtual preview was presented to the patient to visualise the anticipated outcome. Minor modifications were incorporated based on the patient’s feedback, particularly regarding tooth length and contour. This collaborative approach increased patient involvement and improved treatment predictability.

Fabrication of veneers

The six veneers were fabricated chairside for the maxillary anterior teeth using the Midas 3D-printing system (SprintRay). A high-translucency ceramic-filled resin (Crown HT, SprintRay) was selected for its favourable mechanical properties and aesthetic performance (Fig. 3a). Shade A1 was chosen to achieve a bright yet natural appearance consistent with the patient’s facial features and complexion.

Printing and post-processing

The restorations were nested and oriented in the printing software, and supporting structures were generated automatically (Fig. 3b). Printing of the restorations was completed in under 10 minutes, after which the veneers were removed from the capsule/platform (Figs. 4a & b), washed in isopropyl alcohol and polymerised in the NanoCure curing unit (SprintRay). Post-processing required approximately 15 minutes. The veneers were evaluated for thickness and fit (Figs. 4c–e). Each restoration was inspected under magnification to evaluate marginal integrity, fit accuracy, surface texture, shade consistency and the presence of structural defects. The veneers demonstrated good surface quality, marginal accuracy and internal adaptation. Minor adjustments were performed where necessary before finishing and polishing the restorations.

Try-in procedure

Before cementation, a clinical try-in was conducted. The printed veneers were seated on the prepared teeth using a glycerine-based try-in paste where needed to simulate the final cementation result (Figs. 5a–c). Fit, emergence profile, proximal contacts, shade match, translucency, overall smile harmony, phonetics and patient comfort were evaluated. The patient reported a high level of satisfaction with the aesthetic outcome and approved the restorations for definitive placement.

Adhesive cementation protocol

The veneers were bonded according to a protocol intended to support retention and long-term stability. The internal surfaces were cleaned with isopropyl alcohol and silanised according to the manufacturer’s instructions. The tooth surfaces were cleaned with pumice. The enamel was etched with phosphoric acid (Fig. 6a), thoroughly rinsed and dried (Fig. 6b), and a bonding agent was applied according to the manufacturer’s instructions (Fig. 6c).

A light-polymerised resin cement was selected for optimal colour stability. The cement was applied to the veneers, which were then seated under controlled pressure. Excess cement was removed using micro-brushes and dental floss. The resin cement was polymerised through each veneer with a high-intensity curing light from multiple directions to ensure complete polymerisation.

Occlusal adjustment and finishing

After cementation, occlusal stability was carefully evaluated in static and dynamic occlusion. Minor adjustments were made to eliminate premature contacts and ensure harmonious guidance. Final polishing was performed using diamond-impregnated rubber polishers and polishing pastes. This step enhanced surface smoothness and gloss and plaque resistance.

Outcome and follow-up

The definitive restorations demonstrated good marginal adaptation, natural translucency, harmonious tooth proportions, stable occlusal contacts and high surface gloss. The patient reported an immediate improvement in smile confidence and comfort. Functional evaluation confirmed a balanced occlusal relationship and the absence of interferences (Figs. 7a–c).

Postoperative instructions included proper oral hygiene techniques, the use of non-abrasive toothpaste, avoidance of excessive occlusal loading and regular professional check-ups. At the two-week follow-up, the periodontal tissue remained healthy and no complications were observed. The restorations showed stable integration with the surrounding dentition and soft tissue (Figs. 8a–e).

Discussion

This case highlights the potential advantages of integrating 3D printing into chairside restorative dentistry. Compared with conventional laboratory workflows, digital fabrication:

• can reduce treatment time;
• enhance patient comfort;
• allow immediate review and adjustment;
• improve cost-efficiency; and
• support predictable treatment planning.

The minimally invasive approach preserved enamel, which is an important factor for durable bonding. Digital smile design also improved communication between the clinician and the patient, helping align expectations with the planned outcome.

Ceramic-filled printable restorative materials can offer favourable strength and aesthetic properties for veneer applications in selected cases. Proper case selection, strict adherence to bonding and post-processing protocols, and regular follow-up remain essential for long-term success.

Conclusion

This clinical case demonstrates that chairside replacement of composite veneers using a digital workflow and 3D-printing technology can be a reliable and efficient treatment option in selected cases. Through careful diagnosis, conservative preparation, digital planning and precise fabrication, aesthetic and functional outcomes can be achieved in a single visit. The integration of digital dentistry and adhesive principles allows clinicians to deliver patient-centred, minimally invasive and predictable restorations, addressing current demands for efficiency and excellence in aesthetic dentistry.