Chairside CAD/CAM Workflows for Same-Day Restorations 

Chairside CAD/CAM systems have reshaped restorative dentistry by combining digital scanning, computer-aided design, and in-office fabrication into one continuous workflow. Same-day crowns and indirect restorations produced through these systems reduce clinical time, eliminate temporaries, and improve overall predictability. Modern CAD/CAM workflows offer a higher degree of control over restorative quality, accuracy, and material performance than traditional multi-step methods. 

What Exactly is Chairside CAD/CAM Dentistry? 

Chairside CAD/CAM dentistry refers to an integrated digital process where the clinician completes diagnosis, digital impression, design, milling, finishing, and cementation at the same appointment. The workflow is designed for single-unit restorations such as posterior crowns, anterior veneers, inlays, onlays, and select implant crowns. 

This digital approach eliminates manual impression variables and allows the dentist to evaluate margins, occlusion, and internal fit before the restoration is even milled. The result is a streamlined, highly controlled restorative process that enhances both efficiency and clinical precision. 

Key Benefits of Chairside CAD-CAM

Complete Chairside CAD/CAM Workflow 

1. Case Selection and Treatment Planning 

Single-unit posterior crowns, anterior esthetic veneers, inlays, onlays, and minor implant restorations are well-suited for chairside CAD/CAM. 
Considerations include enamel availability, occlusal load, parafunctional habits, gingival health, and finish line visibility. 

2. Tooth Preparation 

Digital workflows require controlled preparation geometry: 

• Rounded internal line angles 
• Smooth axial walls to assist milling accuracy 
• Adequate occlusal reduction (1.0–1.5 mm depending on material) 
• Supragingival or equigingival margins whenever possible 

These features support accuracy and help avoid chipping during milling. 

3. Intraoral Scanning 

Accurate scanning depends on proper tissue management, moisture control, and stable retraction. 
Current scanners offer: 

• Real-time margin identification 
• Reduction analysis 
• AI-supported removal of artifacts 
• Bite alignment verification for occlusal design 

These tools help reduce discrepancies in inter-arch relationships. 

Product- Waldent BLZ IntraVue 900 Ai Intraoral Scanner 

4. Digital Design

CAD software creates anatomical proposals using libraries shaped around natural tooth morphology. 
Adjustments focus on: 

• Marginal integrity 
• Contact area width and height 
• Functional cusp guidance 
• Emergence profiles 
• Occlusal load distribution 

Digital design allows clinicians to visualize and refine the restoration with a higher degree of control than conventional waxing. 

5. Fabrication Phase

Chairside milling units can produce restorations from: 

• Lithium disilicate 
• Hybrid ceramic blocks 
• High-strength zirconia (fast-sinter systems) 
• PMMA for provisional use 

Lithium disilicate offers excellent esthetics and requires crystallization firing. 
Zirconia blocks designed for rapid sintering enable same-day posterior crowns with substantial strength. 

Bur selection, milling strategy, and machine calibration directly influence internal fit and surface texture. 

Products- Dentitude Glass Ceramic Press Ingots LT A3, Dentitude Glass Ceramic CAD-CAM Blocks ( Pack of 5 ), Labodent Zirconia Milling Burs DLC (Nexy Type) 

6. Characterization and Surface Conditioning 

Depending on material: 

• Lithium disilicate is etched with hydrofluoric acid and silanated 
• Zirconia surfaces require airborne abrasion and MDP-containing primers 
• Hybrid ceramics use specific primers for optimal bonding 

Characterization with stains and glazing improves esthetics and surface gloss retention. 

7. Try-In and Cementation

Minimal internal adjustments are expected due to digital precision. 
Cementation protocols vary: 

• Adhesive resin cements for lithium disilicate 
• Self-adhesive resin or RMGIC for zirconia depending on preparation retention 

Final occlusal refinement ensures functional accuracy. 

Cements that can be used- Dentsply Calibra Universal Self Adhesive Resin Cement, Ammdent URC Dual Cure Resin Cement 

Digital workflow of the CAD/CAM crown. (A) Digital impression of the prepared tooth. (B) Digital design of proposed restoration. (C) Swirl marks on the internal surface indicating overmilling. (D, E, F, G, H, and I) Cross-sectional views of the prepared tooth, proposed restoration and overmilled areas. 

Chairside CAD/CAM Compared with Laboratory Workflows

Aspect	Chairside CAD/CAM	Laboratory CAD/CAM
Turnaround Time	Completed in a single appointment	Typically 3–10 days depending on case complexity
Workflow Control	Entire process controlled chairside by the clinician	Design and fabrication outsourced to a technician
Occlusal Adjustability	Immediate adjustments possible before cementation	Adjustments made after lab delivery, may require remakes
Data Accuracy Risks	Minimal risk due to a closed-loop digital workflow	Multiple impression/communication steps increase potential distortions
Operator Skill Dependency	Outcome heavily depends on clinician’s digital design skills	Skilled technician handles design and characterization
Equipment Investment	Requires significant initial purchase of scanner, mill, and furnace	No hardware investment; costs are per-unit via lab fees
Indications	Efficient for single restorations and urgent cases	Preferable for full-mouth rehabilitation, removable prosthetics, and esthetic-demanding anterior work
Patient Experience	One-visit completion, no temporaries	Multiple appointments, temporaries required

Material Considerations

Material selection plays a substantial role in long-term success and must be guided by occlusal demands and esthetic requirements. 

Recent Advancements in Chairside CAD/CAM for Same-Day Restorations 

Conclusion

Chairside CAD/CAM workflows offer a complete, digitally controlled environment for producing same-day restorations with excellent precision, efficiency, and patient acceptance. The integration of high-definition scanning, intelligent design software, and advanced ceramic materials allows clinicians to deliver restorations that meet functional and esthetic demands with minimal procedural complexity. 

As technology continues to evolve, chairside CAD/CAM will further strengthen its role in restorative dentistry, offering clinicians reliable tools for efficient and high-quality patient care. 

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