Complete Digital Workflow for Prosthesis Prototype Fabrication with the Double Digital Scanning (DDS) Technique: A Prospective Study on 16 Edentulous Maxillae.

PURPOSE: To assess the accuracy of fit of milled prosthesis prototypes for completely edentulous patients using a digital workflow. MATERIALS AND METHODS: Sixteen patients received intraoral full-arch digital scans with the double digital scanning (DDS) technique and the generated standard tessellation language (STL) files were superimposed and imported into computer-aided design software (Exocad DentalCAD, exocad GmbH, Darmstadt, Germany) for design. After the design, each master STL file was used for computer-aided manufacturing of the prosthesis prototypes through a complete digital workflow. The primary outcome was the accuracy of fit assessment of the digitally fabricated prototypes on verified patient master stone casts. Two blinded clinicians tested the accuracy of fit of the milled prosthesis prototypes on the verified master stone casts utilizing the screw-resistance test and direct observation. RESULTS: Out of the 16 digitally fabricated prototypes from intraoral full-arch digital scans, all 16 presented with an accurate fit on verified master stone casts. CONCLUSIONS: Digitally fabricated full-arch prosthesis prototypes can be generated with a complete digital workflow leading to clinically acceptable fit.