Chairside Digital Workflow With 3D Printing and CAD/CAM for Partial Restorations

This clinical case report describes the rehabilitation of posterior molars using a fully digital workflow, integrating intraoral scanning, 3D-printed provisional restorations, and CAD/CAM-milled definitive composite restorations.

A 51-year-old woman presented with esthetic concerns regarding her mandibular left first and second molars. Clinical and radiographic evaluation revealed an extensive composite restoration on the first molar and an atypical amalgam restoration on the second molar, with a composite repair on the distobuccal cusp. The treatment plan involved removal of the old restorations, sealing of the root canals with resin-modified glass ionomer, bonding with a two-step adhesive system, coverage with flowable bulk-fill composite, and build-up with conventional composite resin. Both teeth were prepared for partial indirect restorations and digitally scanned. Models and provisional restorations were 3D-printed and temporarily cemented, while definitive composite restorations were milled, surface-treated, and cemented using preheated composite resin. Occlusal contacts were adjusted, and restorations were polished.

The fully digital workflow allowed precise, efficient, and predictable treatment, restoring function, marginal adaptation, and esthetics while preserving healthy tooth structure.

This approach demonstrates the advantages of combining modern adhesive protocols, contemporary restorative materials, and digital technologies for conservative management of complex indirect restorations. The case highlights the potential for digital workflows to improve treatment efficiency, accuracy, and patient satisfaction in restorative dentistry.