3D virtual patient creation with intraoral and facial scanning for zirconia veneers fabrication.

Abstract

Objectives: This clinical case report describes the application of a fully digital workflow for the esthetic and functional rehabilitation of a patient presenting severe fluorosis, internal discoloration, and previously inadequate restorations, utilizing multilayered zirconia prostheses.

Materials and methods: The case integrated intraoral scanning, facial scanning, digital articulators, and CAD/CAM technology to improve treatment accuracy, predictability, and patient-specific adaptation. Initial intraoral and facial scans established functional and esthetic parameters. Occlusal adjustments were performed digitally, simulating condylar movements to ensure optimal occlusal harmony. Digital wax-ups and prototype restorations guided minimally invasive tooth preparations. Multilayered zirconia was selected due to its esthetic qualities, strength, and ability to mimic natural tooth translucency. Restorations were digitally designed, milled, verified intraorally, and bonded under rubber dam isolation.

Results: The digital approach enabled precise occlusal adjustments and substantial esthetic improvements, resulting in enhanced function and natural appearance. Post-treatment assessment revealed improved color stability, optimal marginal adaptation, and high patient satisfaction. The patient was scheduled for regular three-month follow-ups and provided with an occlusal guard to ensure prosthetic longevity.

Conclusion: This report highlights the clinical effectiveness of digital workflows in complex rehabilitations, underscoring benefits such as improved esthetic predictability, functional integration, and durability. Incorporating digital articulators and facial scans notably enhanced treatment precision. Multilayered zirconia restorations demonstrated superior esthetics and function, representing an effective treatment option for patients with severe discoloration and functional impairment.