Digital dentistry — encompassing intraoral digital scanning, computer-aided design and manufacturing (CAD/CAM), and dental 3D printing — has transitioned from the early-adopter fringe to the mainstream of restorative dental practice. Over 200,000 intraoral scanners are now in active clinical use globally; CEREC chairside milling units have fabricated over 50 million restorations; and dental 3D printing has expanded from surgical guide fabrication to direct printing of provisional restorations, surgical splints, and occlusal guards. The evidence base supports digital workflows across multiple dimensions: scanning accuracy, restoration fit, patient experience, and practice efficiency.
Intraoral Scanner Accuracy
Modern intraoral scanners (Dentsply Sirona Primescan, 3Shape TRIOS 5, Align iTero Element 5D Plus, Carestream CS 3800) achieve full-arch scanning accuracy within 50–100 microns (0.05–0.10mm) — comparable to Class A impressions with vinyl polysiloxane (VPS) and plaster pour when measured against industrial gold standards. Single-tooth preparations show scanning accuracy within 20–40 microns. The clinical significance of marginal fit — the most important determinant of crown longevity — shows that CAD/CAM crowns fabricated from intraoral scans achieve marginal gaps of 50–120 microns, comparable to laboratory-fabricated restorations from conventional impressions (80–150 microns). A 2022 Journal of Dentistry systematic review found digital impressions produced significantly fewer incomplete impressions (0.9% vs. 6.8%) and required significantly fewer retakes than conventional impressions.
Same-Day Restorations: The Patient Experience Advantage
CEREC and comparable chairside systems (Planmeca PlanMill, Imes-Icore ceo system) enable complete crown fabrication within 90–120 minutes from preparation to final cementation — eliminating the 2–3 week provisional restoration period and second appointment required by conventional laboratory workflow. Patient satisfaction scores are consistently higher with same-day crown delivery than conventional workflow. For posterior monolithic zirconia crowns (the most common contemporary milled restoration), 5-year survival rates of 96–98% in peer-reviewed outcome studies match or exceed laboratory-fabricated porcelain-fused-to-zirconia. Milled lithium disilicate (e.max) demonstrates 99% 5-year survival for posterior single crowns — the benchmark for ceramic crown longevity. Dental facilities implementing digital workflows should ensure reliable supplies of dental materials and instruments compatible with digital protocols.
