Dr. Reem Attieh and Dr. Mira Orabi
Digital dentistry continues to transform restorative treatment by providing clinicians with high levels of precision, efficiency, and clinical predictability. One of the most important advancements in this field is the integration of artificial intelligence (AI) into digital workflows, which is changing the way restorative procedures are planned, designed, and implemented.
AI has become an essential part of modern restorative dentistry, enhancing the accuracy, consistency, and reproducibility of digital workflows while reducing the time and technical complexity traditionally related to prosthetic design. Specifically, the integration of AI into Computer-Aided Design (CAD) systems has led to the development of advanced digital platforms that automate and improve restorative design procedures. Several companies have contributed to this technological progress, including Dentbird and Atomica, while DentalTwin has more recently introduced an AI-powered CAD software based on a “human-in-the-loop” approach that combines artificial intelligence with clinician-guided decision-making.
Together, these technological developments reflect the ongoing shift toward more intelligent, efficient, and clinically focused restorative workflows, with the potential to improve design precision, simplify treatment procedures, reduce workflow time, and ultimately enhance patient outcomes.
This clinical case describes the chairside replacement of a fractured fixed partial denture (FPD) using a fully digital workflow integrating an AI-powered CAD platform (DentaBRIDGE, DentalTwin, Germany) for the fabrication of a monolithic zirconia fixed dental prosthesis. The workflow enabled an efficient and precise restorative procedure while reducing intraoral clinical adjustments and improving overall treatment efficiency.
case presentation
case presentation
A patient presented with a failure of an old fixed partial denture (FPD) in the mandibular left region (#33-35). Clinical examination revealed that the abutment teeth (33 and 35) had cast-metal posts and cores. Radiographic examination confirmed adequate endodontic treatment of both abutment teeth. Due to the patient’s chief complaint and clinical condition, a fixed partial denture was planned to use a chairside digital workflow.
Stepping into the digital workflow
Stepping into the digital workflow
Following the refinement and optimization of the existing post-and-core preparations, a fully digital chairside workflow was initiated through intraoral data acquisition using an intraoral scanner (AlliedStar, Seoul, South Korea). The acquired STL files were imported into DentalTwin’s AI-powered CAD platform, where the restorative design was performed and finalized. The rapid completion of the scanning and design phases demonstrates the ability of chairside digital workflows to streamline treatment and reduce overall clinical time.
Chairside CAD/CAM Fabrication and Fit Evaluation of the Definitive Restoration
Chairside CAD/CAM Fabrication and Fit Evaluation of the Definitive Restoration
Within approximately 20 minutes of the initial intraoral scan, a finalized STL file was generated and received for manufacturing. The definitive 3-unit FPD was then fabricated from a monolithic zirconia disc (Zolid Bion, Amann Girrbach, Germany) by CAD/CAM subtractive manufacturing (Ceramill Motion 3, Amann Girrbach, Germany).
Following fabrication, the restoration underwent fast sintering in a Ceramill Therm 3 furnace (Amann Girrbach, Germany).
The completed restoration was evaluated on a printed model to ensure satisfactory fit accuracy, marginal adaptation, and proximal contacts before delivery.
Visual evaluation of the intaglio surface demonstrated clean and well-defined restoration margins.
Precision Confirmed. Patient Satisfied.
Precision Confirmed. Patient Satisfied.
During clinical try-in, the restoration demonstrated an excellent passive fit and marginal integrity, requiring only minimal chairside refinements before final cementation. The precision of the workflow facilitated smooth integration of the restoration within the patient’s existing occlusion.
Occlusion was carefully evaluated before definitive cementation to ensure proper functional integration and occlusal harmony without interferences.
The restoration was cemented using a self-adhesive resin cement (TheraCem, Bisco, USA). The final clinical result demonstrated satisfactory esthetic integration, functional rehabilitation, and accurate translation of the digital design into the clinical environment.
In conclusion, the AI-powered CAD system (DentaBRIDGE, DentalTwin, Germany) provides a significant improvement in chairside digital dentistry through enhancing workflow efficiency, restorative precision, and clinical predictability within a fully digital environment. This clinical case demonstrates how an AI-driven chairside workflow, combined with traditional restorative principles, can enhance prosthetic rehabilitation accuracy and efficiency while minimizing chairside corrections.
Furthermore, the present case highlights the expanding role of artificial intelligence in contemporary CAD systems, supporting more standardized, efficient, and clinically reliable restorative procedures.