1. Technological Background
1.1 CAD/CAM-Assisted Milling Processes
The digital production workflow begins with CAD design and continues into CAM, where toolpaths, materials, and milling strategies are defined. Modern CAM systems generate precise, material-specific toolpaths that improve surface quality, fit, and strength of restorations.
Miyazaki & Hotta (2011) demonstrate that CAD/CAM-based production systems offer high precision and consistent results, particularly for crown and bridge restorations.
5-axis milling machines enable the production of complex geometries such as divergent abutments, deep preparation margins, or anatomical occlusal surfaces. Automated tool measurement and monitoring further increase process reliability.
1.2 Open vs. Closed Systems
Open CAD/CAM systems allow the exchange of data formats like STL or PLY, providing laboratories with maximum flexibility when choosing scanners, software, and materials. Closed systems are more standardized but less adaptable.
For automated workflows, open systems often offer advantages—especially when integrating loaders, sintering furnaces, or material stations.
2. What Is Sintering?
Sintering is a thermal densification process in which porous, pre-milled zirconia blanks are heated to temperatures between 1,450–1,600 °C.
During sintering:
Sintering therefore determines:
A correct, material-specific sintering program is essential for the clinical quality of the final restoration.
3. The Irreplaceable Human Factor: Trust and Empathy
3.1 Automated Production of Zirconia Crowns and Bridges
The combination of digital design, automated 5-axis milling, and precise high-temperature sintering furnaces enables zirconia restorations to be produced quickly, reproducibly, and in a standardized manner.
Loader systems enable autonomous milling of multiple jobs in sequence—saving significant time, especially when working with changing indications.
3.2 Night Operation in High-Volume Labs
Large laboratories use automation to increase production capacity without tying up personnel.
Typical workflow:
This dramatically increases machine utilization—and lowers unit costs.
3.3 Efficiency Gains in Small and Medium-Sized Laboratories
Even without full automation, smaller labs benefit from:
This reduces manual labor significantly and enables faster delivery times.
3.4 Integration into Existing Workflows
Thanks to open systems, modern machines can easily be integrated into existing CAD/CAM environments. Clear process steps and staff trained in digital workflows are essential.
4. Benefits for the Target Group
4.1 Reduction of Unit Costs
Key economic advantages of automated processes:
4.2 Higher Process Reliability
Automation reduces operator error and improves repeatability. With zirconia in particular, this leads to more reliable fit and stable material properties.
4.3 Predictable Production Times
Standardized workflows enable:
4.4 Quality Advantages
Improved precision through:
4.5 Manual vs. Automated – Comparison
Factor | Manual | Automated |
Working time | high | low |
Consistency | variable | high |
Unit costs | higher | lower |
Production volume | limited | scalable |
Error risk | higher | low |
5. Challenges / Limitations
5.1 Investment Costs
Modern milling machines and sintering furnaces require upfront investment—but this can be recouped through increased utilization.
5.2 Training Requirements
Digital workflows require trained technicians who understand CAM, material properties, and process optimization.
5.3 Quality Control Remains Necessary
Automation does not replace professional inspection of:
5.4 Material Dependencies
Different zirconia types require specific milling and sintering parameters—standardization is crucial.
5.5 Possible Sources of Error
6. Market & Future Perspectives
The digital dental manufacturing sector is experiencing rapid development. CAD/CAM systems are becoming faster, more precise, and increasingly autonomous. At the same time, dentists and patients expect higher quality, faster delivery, and stable pricing—driving the trend toward highly automated, intelligently networked laboratory infrastructure.
Key developments shaping the market:
6.1 Fully Automated Production Cells
Dental labs are increasingly evolving into micro-industrial production environments.
Automated production cells combine:
Advantages:
24/7 operation without personnel—ideal for high-volume or variable demand.
Benefits:
6.2 AI-Based CAM Strategies
Artificial intelligence is increasingly being integrated into CAM systems.
AI enables:
This improves efficiency and reduces costs through lower rejection rates.
6.3 Predictive Maintenance
Predictive maintenance will become standard in high-end labs.
Machines continuously record data such as:
Software predicts when maintenance is needed.
Benefits:
6.4 Material Science Trends
Key developments:
Next-generation zirconia:
High-strength hybrid materials:
Titanium and CoCr processing:
Better milling strategies and more stable machines make titanium abutments economically producible even in medium-sized labs.
Hybrid Manufacturing (AM + CAM):
Conclusion:
Material innovation and automation are merging. Future systems will automatically select the best parameters for each material batch.
7. Conclusion & Recommendations
Automated milling and sintering processes significantly improve both efficiency and profitability in dental laboratories. Lower unit costs, consistent quality, and predictable production times provide a major competitive advantage.
Recommendations:
7.1 FAQ Section
1. Do automated processes really reduce unit costs?
Yes — fewer manual steps, night production, and lower rejection rates clearly reduce cost per unit.
2. Does automation affect aesthetics?
No — reproducible temperatures and precise CAM strategies actually improve quality stability.
3. Is automation suitable for small laboratories?
Yes — even partial automation (tool management, preset sintering programs) offers strong benefits.
4. Is quality control still necessary?
Absolutely — automation does not replace professional inspection.
