CAD/CAM Milled Restoration

Every milled case at Dani Dental opens with a scan-quality gate. Intraoral scan files (.STL, .PLY, or OBJ) are pulled into 3Shape Dental System for margin verification before any tool path is generated. If a scan shows voids in the margin zone or compression artifacts at the interproximal, the technician assigned to the case contacts the sending office directly, usually within two hours, to resolve before cutting material. That step alone accounts for most of the fit variance labs eliminate in the remake cycle, not the milling itself. Design runs on 3Shape Dental System with material-specific compensation profiles built for each block type in the current inventory: Katana Zirconia UTML, Katana HTML, IPS e.max CAD, and Vita Enamic for hybrid-ceramic indications. Tool paths are generated and reviewed before the file transfers to the five-axis mill. Single-unit posterior cases machine in under 40 minutes of active cut time. Full-arch frameworks, which require more staged roughing passes to hold tolerances across the span, are typically complete in one milling session the same production day the design is approved. Post-milling, zirconia restorations go through a calibrated sintering furnace cycle matched to the specific Katana block density. The lab does not run mixed loads of UTML and HTML in the same sintering cycle; doing so introduces shade variance and translucency inconsistency that shows up at try-in. Each sintering run is logged by block batch number, furnace position, and final temperature profile. That log travels with the case file and is available to the sending clinician on request. Anterior milled restorations, particularly IPS e.max CAD crowns in the upper anterior sextant, go through a hand-characterization step after crystallization. The assigned technician applies surface stain and glaze to match the approved VITA or Vita Linearguide shade, referencing the intraoral photograph the sending office submits at case open. The characterization step is not outsourced and not optional for anterior cases. It is the step most volume mills skip, and it is where most anterior remake requests originate at other labs. Shipping uses padded, case-specific trays inside rigid outer packaging. Each parcel includes a QR-linked fit-verification checklist covering seating depth, contact point pressure, and occlusal clearance. The technician who designed the case, not a general customer service rep, is the first contact if the checklist surfaces an issue at the chairside try-in.