A digital workflow for implant-supported fixed partial dentures using multi-dataset matching

Digital workflows are increasingly used in implant prosthodontics; however, achieving passive fit in implant-supported fixed partial dentures (FPDs) remains challenging because of stitching errors inherent to wide-span intraoral scans and the absence of a physical working cast for accurate titanium-base bonding. These limitations may lead to positional discrepancies and compromised prosthetic accuracy. This article describes a digital workflow for implant-supported FPDs based on stepwise multi-dataset matching. The protocol begins with a preoperative complete-arch scan that serves as the baseline dataset. After implant placement, an intraoperative partial scan with scan bodies is obtained and matched with the baseline dataset to design and fabricate a screw-retained interim restoration. At second-stage surgery, following an adequate osseointegration period for conventional loading, the interim restoration is delivered and used for functional rehabilitation, whereas occlusal and contour adjustments are performed intraorally. For fabrication of the definitive restoration, additional chairside partial scans and laboratory model scans of a verification cast are obtained. Using the verification index as a spatial reference, these datasets are matched with the baseline scan to generate a definitive dataset that incorporates verified implant positions and clinically adjusted prosthetic morphology while limiting reliance on repeated wide-span intraoral scanning. The definitive prosthesis is then fabricated using this dataset and bonded to titanium bases on the verification cast to support the predictability of passive fit. By combining the biologic safety of conventional loading with stepwise multi-dataset matching, this workflow is intended to improve clinical efficiency while supporting prosthetic accuracy in implant-supported FPD fabrication within a digital prosthodontic workflow.