As a dentist, you rely on your lab to transform impressions into reliable restorations for your patients. A dental lab combines material knowledge and technical skill to create each prosthetic. The development method they choose affects fit, durability, and how much adjustment is needed at delivery. Here are some ways dental laboratories produce prosthetic solutions:
Wax and Casting
Wax and casting is a key method for producing metal-based restorations, such as full-coverage crowns, bridges, and partial frameworks. A dental lab starts by creating a wax-up, or 3D model of a patient’s teeth, on a die model using carving tools or milling equipment. The wax pattern defines occlusion, anatomy, and margin placement, all of which are based on the preparation and the opposing arch.
Once the wax model is complete, it’s filled with dental plaster and placed in a burnout furnace to eliminate the wax structure. The hardened plaster creates a dental cast, which is a positive replica of a patient’s teeth. Crowns and other dental appliances are then molded onto the cast with wax.
The wax form is embedded in a special material that takes the shape of the mold. After the wax is melted away, the form is filled with molten metal or ceramic. Vacuum or centrifugal casting methods help achieve a dense metal form that matches the original wax-up. After divesting, your lab trims and polishes the appliance, then verifies the fit on the master model.
Ceramic Layering
When dental appliances require natural translucency and lifelike texture, ceramic layering offers the flexibility to build details by hand. Technicians begin with an opaque layer to neutralize the substructure and create a stable base for the buildup. Shade selection, thickness, and firing cycles are carefully matched to your case requirements to maintain color consistency throughout the process.
The buildup continues with enamel and porcelain, placed in stages to mimic the internal layers of a natural tooth. Surface anatomy is shaped before each firing to preserve fine detail and reduce post-production adjustments. If you have provided the lab with photographs or a shade map, these guide the placement of translucencies, halos, and character lines. Skilled layering helps reduce surface grinding, which preserves strength and aesthetics.
CAM Milling
Computer-aided design (CAD) and computer-aided manufacturing (CAM) offer speed, precision, and consistency when fabricating crowns, bridges, inlays, and implant abutments. Once the digital impression or model scan is received, the design is made with specialized software. Your prescribed anatomy, contacts, and occlusion guides digital model development. Libraries and parameters are adjusted to reflect a patient’s clinical needs, whether you’re restoring a single molar or a full arch. Design approval often happens quickly, especially when communication between you and your lab is streamlined.
After the design is finalized, milling is completed using high-speed rotary instruments on materials like zirconia, lithium, or PMMA. The type of restoration and required strength influence the material choice. Multilayered blocks can be used for gradient shading, which reduces the need for external staining. Precise tool paths and calibration allow for accurate margins and internal fit, minimizing the need for adjustments.
3D Printing
3D printing enhances flexibility and speed in appliance creation, particularly for dentures, try-ins, surgical guides, and night guards. A digital design is developed based on intraoral scans customized with your case details. During printing, light-cured resin is deposited in layers with high accuracy to create the object from the base up. Depending on the nature of the restoration and the amount of detail required on the surface, print resolution and layer thickness are adjusted. Post-processing helps verify the strength and accuracy of the printed appliance. The piece is washed after printing to eliminate excess resin and then cured in a controlled environment of light and temperature.
Injection Molding
Flexible partial dentures and non-metallic frameworks require a combination of strength and comfort that is produced through injection molding. A printed model of the master prosthesis is created from the design you have approved. Like with the wax and casting method, a hollow cast is made, and the prosthesis materials are poured in to harden. Before the material sets, the tooth shade is usually determined. Injection molding, compared to traditional acrylic processing, yields a denser structure. This uniformity allows flexibility in clasps and fit throughout the appliance’s lifetime.
Optimizing Outcomes with Your Dental Lab
Choosing the right production method helps determine how well the appliance supports your treatment goals. Whether you’re restoring function, improving aesthetics, or reducing chairside time, the technique your dental lab uses plays a direct role. A strong working relationship with your lab gives you better control over outcomes and case efficiency. Talk to your dental lab about which methods match your clinical approach and patient expectations.
