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184 THE INTERNATIONAL JOURNAL OF ESTHETIC DENTISTRY VOLUME 13 • NUMBER 2 • SUMMER 2018 CLINICAL RESEARCH A report on a diagnostic digital workow for esthetic dental rehabilitation using additive manufacturing technologies Marta Revilla-León, DDS, MSD Assistant Director and Assistant Faculty at AEGD Program, School of Dentistry, Texas A&M University, Texas, USA José Luis Sánchez-Rubio, RDT Dental Technician, Dental Laboratory 3Dental, Madrid, Spain Adriana Besné-Torre, RDT Dental Technician, Dental Laboratory 3Dental, Madrid, Spain Mutlu Özcan, DDS, Dr med dent, PhD Professor, University of Zurich, Division of Dental Materials Unit, Center for Dental and Oral Medicine, Clinic for Fixed and Removable Prosthodontics and Dental Materials Science, Zurich, Switzerland Correspondence to: Dr Marta Revilla-León Calle Berlin 14, 28922 Madrid, Spain; Tel: +34 619 269 478; Email: [email protected]

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Page 1: A report on a diagnostic digital work ow for esthetic ... · In prosthetic dentistry, current ap-plications of DLP technology are the Introduction Correct treatment planning, with

184THE INTERNATIONAL JOURNAL OF ESTHETIC DENTISTRY

70-6.&����t�/6.#&3���t�SUMMER�����

CLINICAL RESEARCH

A report on a diagnostic digital

workflow for esthetic dental

rehabilitation using additive

manufacturing technologies

Marta Revilla-León, DDS, MSD

Assistant Director and Assistant Faculty at AEGD Program,

School of Dentistry, Texas A&M University, Texas, USA

José Luis Sánchez-Rubio, RDT

Dental Technician, Dental Laboratory 3Dental, Madrid, Spain

Adriana Besné-Torre, RDT

Dental Technician, Dental Laboratory 3Dental, Madrid, Spain

Mutlu Özcan, DDS, Dr med dent, PhD

Professor, University of Zurich, Division of Dental Materials Unit,

Center for Dental and Oral Medicine, Clinic for Fixed and Removable Prosthodontics

and Dental Materials Science, Zurich, Switzerland

Correspondence to: Dr Marta Revilla-León

$BMMF�#FSMJO��� �������.BESJE �4QBJO��5FM�������������������&NBJM��SFWJMMB!SFWJMMBSFTFBSDIDFOUFS�DPN

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Abstract

The digital workflow – from the intraoral scanning, through the CAD design of the facially generated diagnostic digital wax-up, to the CAD-designed and 3D-printed silicone index with the diagnostic mock-up – provides a new approach that avoids the conventional manufacturing

PG� DBTUT�� 5IF�EFWFMPQNFOU� PG� UIF�QSP-cess requires a synchronized workflow and good communication between the dental technician, prosthodontist, and QBUJFOU�� 5IJT� SFQPSU� EFTDSJCFT� B�QSPUP-col for the diagnostic digital sequence for the treatment planning of an esthetic SFIBCJMJUBUJPO�(Int J Esthet Dent 2018;13:184–196)

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EJHJUBM�NPEFMT�WFSTVT�QMBTUFS�DBTUT������ The scan strategy�� ���and the learning curve�� using such devices are essen-UJBM�UP�UIF�GJOBM�PVUDPNF��

Computer-aided manufacturing (CAM) technologies are mainly based on sub-tractive or computer numerical control (CNC) technologies, commonly known as milling or additive manufacturing ".� UFDIOPMPHJFT��8IJMF�NJMMJOH� UFDI-nologies are frequently used in dentistry to fabricate dental prostheses, AM tech-nologies that relate to the fabrication of an object in a layer-by-layer build-up process also have potential for dental BQQMJDBUJPOT���

The American Society for Testing and Materials (ASTM) International’s com-NJUUFF�'���PO�".�5FDIOPMPHJFT�IBT�EF-termined seven AM categories, namely stereolithography (SLA) based on Vat photopolymerization, material jetting, material extrusion, binder jetting, pow-EFS�CFE�GVTJPO�1#' �TIFFU�MBNJOBUJPO �BOE�EJSFDU�FOFSHZ�EFQPTJUJPO��� The di-rect light processing (DLP) AM technol-ogy is very similar to SLA technology, with the main difference being the light TPVSDF��"�WBU�PG�MJRVJE�QIPUPQPMZNFS�JT�exposed to light from a laser in an SLA printer, or a projector in the DLP printer, VOEFS� TBGFMJHIU� DPOEJUJPOT�� *O� UIF�%-1�projector, an image of the 3D model is EJTQMBZFE� PO� UIF� MJRVJE� QIPUPQPMZNFS��Once the exposed liquid polymer sets, the building platform moves down, and the liquid polymer is again exposed to MJHIU��5IF�QSPDFTT�JT�SFQFBUFE�VOUJM� UIF�3D model is built and the vat is drained of liquid, revealing the solidified mod-FM������

In prosthetic dentistry, current ap-plications of DLP technology are the

Introduction

Correct treatment planning, with its corresponding diagnostic wax-up, is essential for a successful esthetic re-IBCJMJUBUJPO�� � The fundamental step is the collection of the diagnostic data gathered from the extraoral and intraoral analysis, the diagnostic casts, the pho-tographic and video documentation, the radiographic evaluation, and the diag-OPTUJD�XBY�VQ����

8JUI� UIF� JODPSQPSBUJPO�BOE�EFWFMPQ-ment of intraoral scanners, computer-aided design (CAD) software, and addi-tive manufacturing (AM) technologies, a complete digital workflow for diagnostic USFBUNFOU� QMBOOJOH� DBO� CF� BDIJFWFE��Digital impressions and CAD tools pro-vide for a potent virtual diagnostic as-sessment for restorative planning that can be realized through AM technolo-HJFT��*O�BEEJUJPO �JU�IBT�CFFO�TIPXO�UIBU�the digital workflow is more efficient than the conventional one in terms of cost and time,� ��as well as being better BDDFQUFE�CZ�QBUJFOUT�� ��

Digital impressions are considered pivotal for the fully digital approach to USFBUNFOU� QMBOOJOH�11 The accuracy of the scanner (trueness and precision <*40������� �%*/���������>�QMBZT�BO�JNQPSUBOU� SPMF��� Trueness relates to the ability of the scanner to reproduce a dental arch as close to its true form as possible without deformation or dis-tortion, while precision (reproducibility) indicates the degree of identical images acquired by repeated scanning under UIF�TBNF�DPOEJUJPOT��� �� Recent studies have shown high levels of accuracy with no statistically significant difference be-tween the measurements obtained from

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fabrication of the cast, custom tray or TVSHJDBM�HVJEF��� The rapid evolution of the market has positioned 3D-printing applications as the latest technologies, although in dentistry limited applications are available, systematically analyzed or validated for basic clinical proced-VSFT��� �� ��

This article describes a digital work-flow starting from intraoral scanning, through the CAD design of the facially generated diagnostic digital wax-up, to the CAD-designed and 3D-printed sili-cone index with diagnostic mock-up for BO�FTUIFUJD�SFIBCJMJUBUJPO�

Case presentation

A 33-year-old patient presented at our private practice with the main request PG� TNJMF� JNQSPWFNFOU�� 5IF� FYUSBPSBM �intraoral, and radiographic evaluations SFWFBMFE� BDDFQUBCMF� PSBM� IFBMUI�� 5IF�following protocol was followed to ana-lyze possible esthetic improvement with a diagnostic wax-up based on a digital XPSLGMPX�

During the first clinical appointment, extraoral photographs and video docu-mentation were made from the right and left frontal and lateral facial position and

Fig 1 Extraoral frontal facial photos (a) at rest, (b) during smiling, (c) of the lower one-third of the face at rest, (d)�PG�UIF�MPXFS�POF�UIJSE�PG�UIF�GBDF�EVSJOH�TNJMJOH�

a b

c d

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lower one-third of the face with closed MJQT �BU�SFTU �BOE�EVSJOH�TNJMJOH�'JH����"�EJHJUBM�SFGMFY�DBNFSB�$BOPO�&04��%�Mark II, Canon) with a macro lens (EF ���NN�G����.BDSP �$BOPO�BOE�B�UXJO�GMBTI�.BDSP�5XJO�-JUF�.5���&9 �$BOPO�XBT�VTFE�

At the same clinical appointment, digital impressions of the maxillary and mandibular arches and interocclusal recordings were made with an intraoral scanning device (TRIOS 3Pod Color, 3Shape) following the manufacturer’s TDBOOJOH�QSPUPDPM��'JSTU �CPUI�UIF�NBO-dibular and maxillary scanning was done from the occlusal, lingual, and CVDDBM�QPTJUJPOT��5IFO �UIF�SJHIU�BOE�MFGU�

lateral intermaxillary recordings were made, covering at least three to four UFFUI�'JH���

After placing a lip retractor (Optra-Gate, Ivoclar Vivadent), the scan area was dried to control the relative isolation when the digital impression was made 'JH����8IFO�UIF�EJHJUBM�JNQSFTTJPO�XBT�completed, the intraoral scanning de-vice created the coded information in Standard Tessellation Language (STL), known as a Direct Connection Mode %$.�GJMF�

The smile analysis revealed an uneven gingival margin level and an asymmet-ric zenith position between both central incisors and the occlusal embrasures of

Fig 2 Intraoral scanning direction in (a) the maxilla, and (b)�UIF�NBOEJCMF�

Fig 3 (a) Maxillary, (b) mandibular, and (c) interocclusal buccal registration completed with an intraoral TDBOOFS�

a b c

a b

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Fig 4 Digital diagnostic wax-up of the maxillary arch from the (a) frontal and (b)�PDDMVTBM�WJFX�

Fig 5 Digital diagnostic wax-up photos merged with facial photos (a) of the frontal view at rest, (b) during smiling, (c) of the lower one-third of the face at rest, and (d)�PG�UIF�MPXFS�POF�UIJSE�PG�UIF�GBDF�EVSJOH�TNJMJOH�

a b

a b

c d

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UIF�NBYJMMBSZ�BOUFSJPS� UFFUI��5IF� MBUFSBM�incisors had the same mesiodistal width, but the mesial line angle was asymmet-SJD��*O�UIF�QSFTFOU�DBTF �BOE�CBTFE�PO�the patient’s request, the objective of the virtual diagnostic wax-up was to reduce the occlusal embrasures from teeth 13 UP��� �BOE�UP�BDIJFWF�UIF�NBYJNVN�QPT-sible symmetry between the contralater-al anterior maxillary teeth using the most DPOTFSWBUJWF�SFTUPSBUJWF�PQUJPO�

The DCM file was then imported to the specific CAD dental software (3Shape %FOUBM� 4ZTUFN � �4IBQF�� "� OFX�XPSL-sheet was created, and the option ‘Anat-omy and temporary on prepared teeth’

Fig 6 (a) Frontal view of the virtual design of the silicone index, and (b) virtual design of the silicone JOEFY�GPS�UIF�EJBHOPTUJD�NPDL�VQ�

Fig 7 (a) Software preparation for the AM process that allows for the positioning of the objects on the building platform, and adding the corresponding supportive material for its fabrication, (b) 3D polymer QSJOUFS�3BQJE4IBQF�%���VTFE�GPS�NBOVGBDUVSJOH�UIF�DBTUT �BOE�(c) printed diagnostic casts on the build-JOH�QMBUGPSN�JNNFEJBUFMZ�BGUFS�NBOVGBDUVSJOH�

a b c

was selected for the diagnostic wax-up PG�UIF�JOWPMWFE�UFFUI��5IF�TQFDJGJD�UPPMT�were used to elaborate the diagnostic XBY�VQ�'JH����6TJOH�UIF�$"%�TPGUXBSF�(RealView Engine, 3Shape Dental Sys-tem, 3Shape) it was possible to super-impose the virtual model and the digi-tal diagnostic wax-up onto the patient’s QIPUPHSBQIT�'JH����8IFO�UIJT�QSPDFTT�was completed, the STL file of the virtual XBY�VQ�XBT�FYQPSUFE�

Thereafter, a new worksheet on the specific CAD dental software (Model #VJMEFS ��4IBQF�%FOUBM�4ZTUFN ��4IBQF�was created, and the option ‘Create a model’ was selected for the maxillary

a b

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Fig 8 (a) Maxillary and mandibular AM diagnostic casts, (b) diagnostic wax-up on the maxillary and mandibular casts, (c)�".�TJMJDPOF�JOEFY�'-'-(3���SFTJO�GPS�UIF�EJBHOPTUJD�NPDL�VQ �BOE�(d) 3D-printed TJMJDPOF�JOEFY�PO�UIF�EJBHOPTUJD�NBYJMMBSZ�DBTU�

Fig 9 Intraoral photos of the (a) baseline situation, (b) silicone index during try-in, and (c) diagnostic NPDL�VQ�

a b c

BOE�NBOEJCVMBS�BSDI�EFUBJMT��5P�DSFBUF�the casts for the digital impression, the DCM of the intraoral scanner was im-ported, and the virtual models were cre-ated using the specific dental software

UPPMT��8IFO�DPNQMFUFE � UIF�45-� GJMF�PG�UIF�PSJHJOBM�DBTUT�XBT�FYQPSUFE��'PS�UIF�cast of the diagnostic wax-up, the steps were repeated, importing the STL file of UIF�WJSUVBM�XBY�VQ�

a b

c d

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Next, a new worksheet on the specific CAD dental software was created, and the option ‘Appliance positioning guide’ XBT� TFMFDUFE�� 5IF� TQFDJGJD� TPGUXBSF�tools were used to design the silicone index, including at least one tooth distal to the last tooth involved on the diagnos-UJD�XBY�VQ�'JH���

The STL files of the digital impression and the diagnostic wax-up casts were used to manufacture the models using a DLP 3D printer (3Dental Dental Labora-UPSZ � 3BQJE4IBQF� %�� � 3BQJE4IBQF�'JH�� �XJUI�B����çN�MBZFS�UIJDLOFTT�PG�photopolymer (NextDent Model, Oker DPMPS �/FYU%FOU�7FSUFY�%FOUBM�GPMMPXJOH�the manufacturer’s recommendations

SFTPMVUJPO���øçN�GPS�Y Z�BYJT ���øçN�GPS�[�BYJT��XBWFMFOHUI�����ON�'JH����

The post-processing procedures of the 3D-printed casts were carried out following the manufacturer’s recommen-EBUJPOT��5IF�DBTUT�XFSF�QMBDFE�JO�B�CBUI�PG�����JTPQSPQZM�BMDPIPM�GPS���NJO�UP�SF-move the non-polymerized photopoly-NFS� SFTJO�� "GUFS� DMFBOJOH� BOE� ESZJOH �they were placed in a UV-light polymer-J[BUJPO�EFWJDF�0UPGMBTI �#&(0�GPS�GJOBM�QPMZNFSJ[BUJPO����NJO�BU�����ON�

The STL file was used to manufac-ture the silicone index using a DLP 3D QSJOUFS� 'PSNø �� 1SJOUFS � 'PSNMBCT�XJUI�B�QIPUPQPMZNFS�SFTJO�'-'-(3���SFTJO �black color, FormLabs) following the

Fig 10 Facial photos (a) of the frontal view at rest, (b) during smiling, (c) of the lower one-third of the face at rest, and (d) of the lower one-third of the face during smiling with the diagnostic mock-up in situ�

a b

c d

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manufacturer’s recommendations (res-PMVUJPO� ��ø çN� GPS� Y Z�BYJT� BOE� [�BYJT��XBWFMFOHUI� ����ON� 'JH���� 'PS� UIF�post-processing procedures, the sili-DPOF�JOEFY�XBT�QMBDFE�JO�����JTPQSPQZM�BMDPIPM�GPS����NJO �ESJFE �BOE�QPMZNFS-ized in a SLA-DLP UV-light device (Post-DVSF�TUBUJPO �'PSN-BCT�GPS����NJO�

During the second clinical appoint-ment, the 3D-printed silicone index was USJFE�JO�UIF�QBUJFOU�T�NPVUI�'JH�� �NBL-JOH�TVSF�UIBU�JU�XBT�DPNQMFUFMZ�TFBUFE��For the diagnostic mock-up, an autopo-lymerized composite resin provisional material (Structur 3, A1 color, Voco) was used to fill the silicone index, which was UIFO� QMBDFE� BHBJO� JO� UIF�NPVUI�� "GUFS�

complete seating of the resin compos-ite, the silicone index and the excess XFSF�SFNPWFE�'JH���

The second clinical appointment was completed after all photographs and vid-eo recordings of the diagnostic mock-up from the patient’s mouth had been made, following the same protocol as in the first DMJOJDBM�BQQPJOUNFOU�'JH����

After receiving the patient’s consent, a direct composite resin restoration (Enamel Plus HFO, Micerium) was made on the maxillary anterior teeth following the shape and tooth position of the diag-OPTUJD�NPDL�VQ��*O�PSEFS�UP�USBOTGFS�UIF�information from the diagnostic wax-up to the direct composite restorations, the

Fig 11 Facial photos (a) of the frontal view at rest, (b) during smiling, (c) of the lower one-third of the face at rest, and (d) of the lower one-third of face during smiling with the restorations in situ�

a b

c d

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3D-printed silicone index was cut lon-gitudinally in the buccoincisal direction and used as a guide for the first lingual layer build-up of the composite restor-BUJPOT�'JH����

Discussion

The virtual diagnostic wax-up is an inex-pensive tool for the simulation of the fi-OBM�USFBUNFOU�PVUDPNF��'VSUIFSNPSF �UIF�number of manual steps as well as some physical shortcomings such as distor-tion of the impression material may be reduced when a digital workflow is em-QMPZFE��� ��

The protocol described in this report is a combination of digital and analog procedures, where the digital impres-sion was made using an intraoral scan-ning device, the diagnostic wax-up was prepared virtually, and the casts and silicone index were fabricated using ".�UFDIOPMPHJFT��)PXFWFS � JO�PSEFS� UP�be more conservative, a conventional analog procedure was pursued using a EJSFDU�DPNQPTJUF�SFTJO��

For documentation purposes of the presented case, the diagnostic AM casts and the maxillary diagnostic AM XBY�VQ�DBTU�XFSF�GBCSJDBUFE��)PXFWFS �they were not needed, as the printed silicone index represents the connec-tion element between the virtual diag-OPTUJD�XBY�VQ�BOE�UIF�QBUJFOU�T�NPVUI��The protocol presented could be modi-fied when the mock-up required some modifications, which should preferably be performed directly in the patient’s NPVUI��*O�UIBU�DBTF �UIF�WJSUVBM�EJBHOPT-tic wax-up will not correlate with the final NPDL�VQ��BEEJUJPOBMMZ �JU�XJMM�OPU�DPSSFMBUF�

with the desired final shape and tooth QPTJUJPO�PG�UIF�GVUVSF�SFTUPSBUJPOT��5IVT �the ideal sequence would be a new digi-tal impression of the final mock-up using the intraoral scanning device as well as the use of a DCM that is obtained to de-sign and manufacture a new 3D-printed TJMJDPOF�JOEFY�

The AM silicone index has certain ad-WBOUBHFT�PWFS�B�DPOWFOUJPOBM�POF��%VS-ing its digital design, the borders of the silicone index could be controlled more precisely at the gingival margin, and a more homogeneous thickness could be achieved compared to a manually GBCSJDBUFE� TJMJDPOF� JOEFY�� $FSUBJOMZ �the learning curve to understand and acquire minimum control of the latest digital technologies is crucial to the final PVUDPNF������ The clinician and dental technician require specific training to master the use of an intraoral scanner, CAD software, and AM technologies, especially where a completely digital XPSLGMPX�EPFT�OPU�QSFTFOUMZ�FYJTU�

Since taking photographic records of the natural, social smile of the patient is not an easy task, video recording has CFFO�SFDPNNFOEFE�� A special feature of some CAD dental software programs allows for the alignment between the three-dimensional (3D) virtual model BOE� UIF� UXP�EJNFOTJPOBM� �%� QIPUP-graphs after at least four correspond-JOH�QPJOUT�IBWF�CFFO�NBSLFE��"�DVSSFOU�limitation of this system is the merging of the 3D virtual model of the patient XJUI� B� TUBUJD� �%� JNBHF�� /FWFSUIFMFTT �the presented workflow enhances the visualization of the proposed treatment GPS�UIF�QBUJFOU��(PPE�DPNNVOJDBUJPO�JT�crucial to achieving successful smile design and treatment planning, where

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the treatment goals need to be deter-mined in agreement with the interdisci-plinary team, and with the consent of the QBUJFOU��%JHJUBM�UPPMT�USFNFOEPVTMZ�GBDJMJ-tate and enhance this bidirectional flow PG�DPNNVOJDBUJPO�

Conclusion

In this report, a digital workflow was presented starting with extraoral pho-tographs, video documentation, and intraoral digital impression taking, fol-lowed by the CAD design of the facially generated diagnostic digital wax-up, a CAD-designed and 3D-printed silicone

index with a diagnostic mock-up that eliminated the need for conventionally NBOVGBDUVSFE�XBY�VQT�BOE�DBTUT��

Conflict of interest

The authors did not have any commer-cial interest in any of the materials used JO�UIJT�TUVEZ�

Acknowledgment

The authors acknowledge all the team NFNCFST�PG�UIF�#F�:PVSTFMG�-B�.PSBMFKB�Dental Clinic for their support and help documenting and developing the pre-TFOU�BSUJDMF�

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ics of Anterior Fixed Prostho-EPOUJDT��$IJDBHP��2VJOUFT-TFODF ���������o���

��� (PMETUFJO�3&�FE��&TUIFUJDT�in Dentistry, Vol 1: Principles, Communication, Treatment .FUIPET �FE����0OUBSJP��#$�%FDLFS ��������o���

��� 3VGFOBDIU�$3��'VOEBNFOUBMT�PG�&TUIFUJDT��$IJDBHP��2VJO-UFTTFODF ����������o����

��� "DLFSNBO�.# �"DLFSNBO�+-��Smile analysis and design in UIF�EJHJUBM�FSB��+�$MJO�0SUIPE�������������o����

��� 'SBEFBOJ�.��&TUIFUJD�3FIB-bilitation in Fixed Prostho-dontics, Vol 1: Esthetic Analysis: A Systematic Approach to Prosthetic Treat-NFOU��$IJDBHP��2VJOUFT-TFODF ���������o���

��� 4QFBS�'. �,PLJDI�7(��"�multidisciplinary approach to FTUIFUJD�EFOUJTUSZ��%FOU�$MJO�/PSUI�"N�������������o����

��� -FF�+4 �(BMMVDDJ�(0��%JHJ-UBM�WT��DPOWFOUJPOBM�JNQMBOU�impressions: efficiency PVUDPNFT��$MJO�0SBM�*NQMBOUT�3FT�������������o����

��� +PEB�5 �#SÊHHFS�6��%JHJUBM�WT��conventional implant pros-UIFUJD�XPSLGMPXT��B�DPTU�UJNF�BOBMZTJT��$MJO�0SBM�*NQMBOUT�3FT��������������o�����

��� 8JTNFJKFS�% �.BOT�3 �WBO�(FOVDIUFO�. �3FJKFST�)"��Patients’ preferences when comparing analogue implant impressions using a poly-ether impression material versus digital impressions (Intraoral Scan) of dental JNQMBOUT��$MJO�0SBM�*NQMBOUT�3FT��������������o������

����+PEB�5 �#SÊHHFS�6��1BUJFOU�centered outcomes compar-ing digital and conventional implant impression proced-ures: a randomized crosso-WFS�USJBM��$MJO�0SBM�*NQMBOUT�3FT���������F���oF����

����$ISJTUFOTFO�(+��*NQSFTTJPOT�are changing: Deciding on conventional, digital or EJHJUBM�QMVT�JO�PGGJDF�NJMMJOH��+�"N�%FOU�"TTPD���������������o�����

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Page 13: A report on a diagnostic digital work ow for esthetic ... · In prosthetic dentistry, current ap-plications of DLP technology are the Introduction Correct treatment planning, with

196THE INTERNATIONAL JOURNAL OF ESTHETIC DENTISTRY

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