1. Technological Background
Automation in the dental laboratory is based on the consistent digitalization of the entire production chain. Digital milling machines form the core of a CAD/CAM system consisting of several technological components. Only through the interaction of scanner, CAD software, CAM strategy, and machine-based manufacturing can stable, reproducible, and economically scalable lab processes be achieved. (Reiss, Schmidt & Mehl, 2020)
Modern lab milling machines increasingly follow industrial standards — both in terms of precision and repeatability as well as their ability to be automated. Features such as automatic blank changers, tool measurement, adaptive process monitoring, or cloud-based machine communication all originated in industrial automation and have now found their way into dental manufacturing environments.
The following sections outline the key technological components that form the foundation of automated manufacturing processes.
1.1 CAD – Digital Design
The CAD process is the conceptual foundation of every digital workflow. Design software for dental laboratories enables:
• anatomical and reduced designs
• implant prosthetics (abutments, bars, superstructures)
• telescopic technology
• splints, models, temporaries
• complex variants such as multilayer restorations or segmented bar constructions
Modern CAD software uses AI-powered functions for automatic shaping, occlusion analysis, and morphological adjustment. Crucial for automation is the ability to use standardized design templates and repeatable setups, so designs do not need to be created manually from scratch every time. (Miyazaki et al., 2009; Zaruba & Mehl, 2014)
1.2 CAM – Calculation of Toolpaths
In the CAM step, the CAD model is translated into machinable toolpaths. The quality of the strategy determines: (Guth et al., 2013; Ender, Zimmermann & Mehl, 2016)
• fit precision
• surface quality
• material utilization
• machining time
• tool wear
Modern CAM software uses validated milling strategies precisely matched to the material, tools, spindle, and machine kinematics.
Key elements of automated CAM systems:
• automatic tool selection
• automatic rest-material machining
• nesting algorithms for multi-unit or serial production
• automatic collision checks
• open vs. closed CAM strategies
High process stability is achieved when CAD, CAM, and machine work in close alignment.
1.3 Digital Milling Technology in the Dental Laboratory
Lab milling machines differ significantly from chairside devices. They are often more powerful, robust, and suitable for multi-shift operation.
Key features of modern lab mills:
• 5-axis simultaneous machining for complex geometries
• high-performance spindles (up to 3 kW)
• automatic tool changers (10–30 tools)
• multi-material capability (zirconia, PMMA, wax, PEEK, CoCr, titanium, glass ceramics)
• sensor-based process monitoring
• automatic blank/disc changers
• 24/7 operation capability
The ability to operate for several hours, or even overnight, without user interaction (“lights-out manufacturing”) is a key driver of lab automation.
1.4 Material Diversity for Automated Manufacturing Processes
Today’s digital milling machines process a wide range of dental materials:
Material | Application | Relevance for Automation |
Zirconia | Crowns, bridges, telescopes | Very high – highly standardized, nesting-friendly |
PMMA | Provisionals, splints | Excellent for serial production |
Wax | Cast objects | Fast processing, minimal tool wear |
PEEK/PEKK | Primary parts, special frameworks | High durability |
Titanium/CoCr | Implant prosthetics | Requires powerful machines |
Zirconia and PMMA especially benefit from automated nesting because they are ideal for multi-unit production.
1.5 System Integration & Degree of Automation
The degree of automation in digital lab mills ranges from semi-automatic to fully autonomous:
• Manual loading: entry-level, low automation
• Semi-automated systems: tool changers, sensors, CAM automation
• Fully automated systems:
– automatic blank changing
– tool magazines
– automated cleaning
– remote monitoring
– night shifts without an operator
Seamless integration with lab software (ERP, job management, cloud platforms) allows labs to digitally assign jobs, monitor machine status, and track production progress in real time.
2. Practical Applications / Use Cases
Digital milling machines have fundamentally changed the dental laboratory because they standardize and automate what used to be time-consuming, manual, and error-prone steps. Importantly, automation affects not only material processing but entire process chains — from job management to nesting to overnight production.
The following sections highlight key use cases where automation produces significant efficiency gains.
2.1 Fully Automated Zirconia Production
Zirconia production is one of the most important application areas for digital milling machines. Automated systems enable: (Sailer et al., 2018; Zhang & Lawn, 2018)
• full overnight production
• series manufacturing of crowns and bridges
• automatic nesting of large case volumes
• material management via blank changers
• continuous tool monitoring and automatic tool changes
Zirconia is ideal for automation due to its homogeneity and nesting friendliness. High-speed sintering furnaces complement the workflow and significantly reduce total turnaround time. (Zhang & Lawn, 2018)
2.2 Automated Night Production ("Lights-Out Manufacturing")
Major potential arises when digital milling systems can run for many hours or entire shifts without manual intervention.
Benefits:
• production outside regular working hours
• significantly higher machining uptime (up to 24/7)
• consistent utilization independent of staffing
• scalability without additional skilled labor
Automatic blank changers, digital machine monitoring, and remote access make this operation safe and controllable.
2.3 Serial Production of Repetitive Work
Many labs benefit enormously from automation in high-repetition areas:
• PMMA splints
• bite appliances
• temporaries
• templates
• surgical guides
PMMA splints and long-term temporaries are ideal for fully automated overnight production due to their high reproducibility.
2.4 Complex Suprastructures & Implant Prosthetics
Even high-end precision work increasingly benefits from digital milling:
• custom abutments
• screw-retained bridges
• telescopic work
• bar constructions
• titanium and CoCr processing
High-performance machines with appropriate spindles and stable 5-axis kinematics enable precision that is nearly impossible to achieve manually.
2.5 Workflow with Automated Peripheral Devices
Automation does not end at the milling machine — modern labs use an interconnected ecosystem:
• automatic tool measurement
• material identification systems (RFID)
• dust extraction and filtration automation
• intelligent blank detection
• digital consumable management
These components reduce error sources, monitor maintenance processes, and ensure uninterrupted production workflows.
2.6 Integration into Lab Software & Digital Job Systems
Many labs today use:
• ERP systems
• digital lab prescriptions
• cloud platforms for job control
• automated production lists
• remotely monitored machine parks
The combination of lab software and automated milling technology enables end-to-end digital value creation — from order intake to delivery.
2.7 Addressing Skill Shortages & Workload Relief
Automation helps counter the shortage of skilled dental technicians by:
• shifting repetitive work to machines
• allowing qualified staff to focus on higher-value tasks
• absorbing production peaks
• reducing overtime
Labs can significantly increase output without proportionally increasing staff.
3. Benefits for the Target Group
Digital milling machines not only revolutionize individual production steps — they transform the entire value chain of a dental laboratory. For labs facing high quality standards, time pressure, and a shortage of skilled workers, automation provides major strategic, economic, and technological advantages.
3.1 Increased Efficiency and Throughput
Automation enables significantly higher production capacity without hiring additional technicians.
Effects:
• continuous production via night and weekend shifts
• parallel processing of many cases (zirconia, PMMA, wax)
• less downtime
• shorter turnaround times across the entire lab
Large labs and milling centers especially benefit from maximum machine utilization through automated blank changers and intelligent nesting algorithms.
3.2 Reproducible Precision and Reliable Quality
Digital milling machines deliver high-precision results independent of:
• personal condition
• technician experience
• manual errors
Repeatability is especially important for:
• serial production
• implant prosthetics
• telescopic work
• CAD-based secondary structures
• highly aesthetic zirconia frameworks
Automated tool measurement and sensor process monitoring ensure consistently high quality.
3.3 Economic Advantages & Fast ROI
Automation reduces cost per manufactured unit.
Economic levers:
• less waste
• more output with the same team size
• reduced manual labor
• predictable material and tool costs
• significantly higher machine uptime
Many labs achieve ROI within 12–24 months depending on material mix and production volume.
3.4 Improved Delivery Times and Reliability
Automation yields substantial competitive advantages:
• significantly increased on-time delivery
• easier accommodation of rush cases
• bottlenecks reduced through overnight production
• more reliable delivery promises for clients
This is particularly important for implant restorations and high-end zirconia work.
3.5 Scalability & Growth Potential
Automation allows labs to expand without proportionally increasing staff.
Scalable scenarios:
• additional machines instead of additional personnel
• parallel manufacturing of numerous jobs
• modular expansion — start small, later upgrade
• growth from a traditional lab to a milling center
The machine becomes a multiplier of existing capacity.
3.6 Relief from Skill Shortages
The dental industry suffers from a structural shortage of skilled technicians. Automation helps:
• offload repetitive tasks
• enable technicians to focus on aesthetic and complex work
• avoid workflow bottlenecks
• increase job satisfaction
Teams can dedicate more time to craftsmanship, customization, and customer service.
3.7 Future Security & Competitiveness
Automation is already a key success factor in competition with:
• other high-end labs
• industrial production centers
• international low-cost manufacturers
Digital milling systems provide the foundation for long-term market viability — with higher efficiency, better quality, and stronger customer retention. (Reiss, Schmidt & Mehl, 2020)
4. Challenges / Limitations
Despite the advantages, several challenges must be considered when implementing automated milling systems.
4.1 High Initial Investment
Automated lab mills — especially those with:
• blank changer
• tool magazine
• powerful 5-axis kinematics
• industrial spindle
• automation interfaces
— require a substantial investment.
Additional costs include:
• CAD/CAM software licenses
• sintering furnaces / peripherals
• tools & consumables
• maintenance and service
A sound business case is essential.
4.2 Training Requirements & Skill Development
An automated system becomes valuable only when the team can use it confidently:
• understanding material properties
• competent CAM use
• correct tool selection
• nesting knowledge
• machine handling
• recognizing process errors
• interpreting sensor feedback
Labs often need a structured onboarding and training plan.
4.3 Process Validation & Quality Control
Automation does not replace quality control.
Risks that must be monitored:
• tool wear and tool breakage
• material lot variations
• poor nesting → fracture risk
• insufficient sintering shrinkage compensation
• undetected machine deviations
Regular calibration, tool measurement, and test jobs are mandatory.
4.4 Material & Indication Limitations
Not all restorations can be fully automated.
Limitations include:
• complex aesthetic layering
• fine individual textures
• multi-unit titanium or CoCr frameworks (machine-dependent)
• delicate structures requiring manual finishing
Dental craftsmanship remains indispensable.
4.5 Dependency on Software & Digital Infrastructure
Without stable digital infrastructure, production interruptions occur.
Risks:
• software or license issues
• server/network failures
• cloud outages
• compatibility issues between CAD, CAM, and machine
• problematic update processes
A robust backup concept is essential.
4.6 Maintenance, Wear, and Process Stability
Automated systems require regular maintenance to ensure process safety:
• spindle servicing
• tool magazine inspection
• extraction and filtration systems
• machine cleaning
• guide rails/linear axes
• axis calibration
Neglected maintenance leads to faster loss of precision.
4.7 Economic Risk with Low Utilization
High-efficiency milling centers perform best with strong utilization. Smaller labs must evaluate:
• realistic weekly production volume
• whether night production is worthwhile
• whether outsourcing to a milling center might be more economical
Automation is most profitable when utilization is high or growing.
5. Market & Future Outlook
Digitalization and automation in the dental laboratory are at a turning point. While CAD/CAM systems were once considered additions to traditional dental technology, they are now essential to modern production.
5.1 Growing Market Acceptance & Professionalization
Acceptance of digital manufacturing is rising among labs and dentists.
Reasons:
• rising demands for speed and precision
• shortage of skilled technicians
• cost pressure
• demand for aesthetic, repeatable restorations
• clear ROI potential
Medium and large labs increasingly invest in 24/7-capable automated systems.
5.2 AI-Powered Workflows
Artificial intelligence is becoming more prevalent in dental fabrication:
• automatic margin detection
• AI-based nesting
• tool wear & error prediction via machine learning
• automated CAM strategies
• intelligent stress forecasting
AI is becoming a key efficiency driver in both CAD and CAM.
5.3 High-Speed Materials & Ultra-fast Sintering
Trends toward materials that can be processed and sintered faster:
• high-speed zirconia (sinter < 30 minutes)
• multilayer zirconia
• high-strength hybrid ceramics
• optimized PMMA for serial production
These materials drastically reduce production time.
5.4 Fully Automated Production Cells ("Digital Dental Factory")
The future lies in networked production cells with:
• multiple synchronized milling and printing units
• automatic blank/tool changers
• centralized production management
• cloud-based monitoring
• robotic logistics (pick-and-place)
These systems allow highly scalable dental manufacturing.
5.5 Cloud Infrastructure & Remote Monitoring
Labs benefit from:
• cloud-based job management
• remote machine access
• real-time monitoring
• predictive maintenance
• automated documentation
Remote oversight allows safe control outside working hours.
5.6 Rise of Open Systems
Open hardware and software architectures are trending:
• flexible scanner selection
• interchangeable CAM tools
• compatible materials from various manufacturers
• lower long-term costs
• improved integration into lab IT
• better future security
Open systems are increasingly becoming the standard.
5.7 Shift Toward Hybrid Practice-Lab Models
Lab–practice collaboration is evolving:
• practices produce simple cases chairside
• labs handle complex or aesthetic cases
• hybrid workflows are economically optimal
Automated lab production ensures quality and rapid turnaround.
5.8 Role of Manufacturers Such as imes-icore
Manufacturers like imes-icore bring industrial automation standards into dental fabrication:
• robust 5-axis systems
• automatic blank changers
• precise industrial spindles
• open CAD/CAM integration
• scalable lab and milling-center solutions
These technologies form the basis of digital production cells already in use worldwide.
6. Conclusion & Recommendations
Automation through digital milling machines has become one of the most powerful transformation levers in the modern dental laboratory. While traditional processes relied heavily on manual expertise and human capacity, automated CAD/CAM systems now provide a production environment that is more precise, efficient, and scalable.
Digital milling machines do more than increase output — they transform the entire business model of a lab. They enable reproducible quality, reduce error sources, and improve overall economic performance. In the context of skill shortages, rising material diversity, and cost pressure, automation is becoming essential for long-term competitiveness.
To fully leverage automated manufacturing, labs should follow these recommendations:
6.1 Strategic Workflow Analysis
Before investing, labs should examine:
• which cases generate the highest volume
• which tasks are highly repetitive (splints, zirconia, PMMA)
• which manual steps create bottlenecks
• where time and quality losses occur
A clear process analysis identifies the most promising areas for automation.
6.2 Choose the Right System Architecture
Key factors:
• powerful 5-axis milling machines
• automatic blank and tool changers
• open CAD/CAM systems
• industrial-grade components
Open platforms generally offer the best long-term investment security.
6.3 Invest in Training & Qualification
Automation works only when the team understands the workflow:
• material science
• CAD/CAM competence
• process control
• tool and machine maintenance
• nesting proficiency
A trained team significantly increases profitability.
6.4 Implement Advanced Quality Management
Recommended:
• regular machine calibration
• tool measurement & monitoring
• validated sintering parameters
• standardized nesting templates
• digital documentation of all manufacturing parameters
This ensures stable quality even at high automation levels.
6.5 Regularly Evaluate Key Economic Metrics
Labs should track:
• utilization
• material & tool costs
• scrap rate
• production time
• ROI
Continuous monitoring optimizes profitability.
6.6 Think Long-Term: The Path to the "Digital Dental Factory"
As automation progresses, the lab becomes a highly modern production cell that is:
• scalable
• labor-efficient
• continuously productive
• highly precise
• data-driven
This is no longer a future scenario — many labs are already on this path.
Summary
Digital milling machines are not just a technical addition — they are a fundamental building block for future readiness, competitive strength, and economic stability in dental laboratories.
Labs that invest now secure:
• higher efficiency
• controlled quality
• more production capacity
• lower cost per unit
• stronger market position
• a modern working environment
Automation is not just a technological step forward — it is a strategic advantage.
FAQ section
1. Which laboratory processes are best suited for automation?
Repeatable, high-volume production processes such as zirconia, PMMA, and wax milling, splint fabrication, models, and temporary restorations are particularly efficient for automation. Implant abutments and telescopic work also benefit greatly from automated CAM strategies.
2. How does an automated milling machine pay for itself economically?
Continuous production, lower scrap rates, reduced manual work steps, and greatly increased machine running times result in a clear economic advantage. Many laboratories achieve a ROI within 12–24 months, depending on case volume and material mix.
3. Which materials are particularly suitable for automated processes?
Zirconia and PMMA are ideal for fully automated series production because they can be nested precisely. Wax is suitable for fast cast objects and prototypes. Titanium and CoCr require more powerful machines, but also benefit from automated process control.
4. Do you need a large laboratory to use automation economically?
No. Even small laboratories benefit from automation, especially if there is a lot of repetitive work. However, larger laboratories and milling centers achieve the highest economies of scale through 24/7 production and series production.
5. How reliable are automatic blank and tool changers?
Modern systems are highly reliable and designed for industrial use. Automatic tool measurement, sensor monitoring, and adaptive error management increase process stability. Regular maintenance ensures consistent quality.
