Current intraoral scanners (IOS) enable direct impression taking for computer-aided de-sign/computer-aided manufacturing (CAD/CAM) posts and cores (P+C) with subsequent milling out of monolithic materials. The aim of this in vitro study was to systematically investigate the accuracy of CAD/CAM-P+C in a fully digital workflow, considering different IOS impression methods (Primescan (PRI), Trios4 without (TRI) and with scanpost (TRI+SP)) (Part A), and CAD/CAM milling of zirconium dioxid (ZIR) and resin composite (COM)-P+C (Part B). Five human models were developed in this study. Micro-CT imaging was used as a reference (REF). For Part A, the models were scanned 12 times for each impression method. Then, IOS datasets (n = 180) were superimposed with REF, and scan accuracy was determined using 3D software (GOMInspect). For Part B, one CAD/CAM-P+C (n = 30) was milled for each model, impression method, and material. The triple-scan method was applied using an industrial scanner (ATOS) to determine the accuracy of the fit. Statistical analysis was performed using analysis of variance (ANOVA, p < 0.05). Part A showed for PRI significantly lower accuracy than TRI and TRI+SP (p < 0.05). The data of Part B revealed significantly higher accuracy for ZIR than for COM (p < 0.05). Within the limitations of this study, CAD/CAM-P+C of the ZIR can be recommended for fabrication in a fully digital workflow regarding the accuracy of fit.

To measure the internal fit of the computer-aided designed/computer-aided manufactured (CAD/CAM) crowns, a new scanner-based chairside approach was investigated in patients, and the results were compared to the established silicone replica technique and a digital laboratory replica method. Thirty full-coverage crown preparations were included. Based on a digital impression with an intraoral scanner (IOS, Trios 3), three CAD/CAM measurement copings (‘COM’, resin composite; ‘ZIR’, zirconium dioxide; ‘NPA’, non-precious alloy) were fabricated for each tooth preparation. The internal fit of the measurement copings was analyzed with three different evaluation methods: IOS-based digital approach (D-IOS), digital replica method with laboratory software (D-GOM), and conventional silicone replica technique (CV-SR). The congruence between the determined target parameter of the 80-µm cement space and the actual measured internal gap was investigated. Statistical analysis was performed by ANOVA (p-value < 0.05). No significant difference was determined between the three evaluation methods. However, significant differences were observed for the three coping materials (p-value < 0.05), the single measurement position (marginal, axial, and occlusal fit) (p-value < 0.05), and the interaction between the coping material and the measurement position (p-value < 0.05). COM revealed the smallest internal gap, followed by ZIR and NPA. Regardless of the coping material, the occlusal gap was higher than the axial and marginal gaps. Furthermore, only the internal gaps of the marginal area almost matched the target parameter of 80-µm for the cement space. D-IOS is effective for measuring internal fit of single crowns in different clinical settings.

Since one-third of persons suffer a dental trauma, treatment of anterior teeth using post and core (PC) is becoming important. In teeth with extensive destruction, cast PC (CPC) remain the "gold standard", even though they lead to aesthetic impairment and have a mismatching elastic modulus to that of dentin. Prefabricated fibre-reinforced posts have elastic modulus similar to that of dentin but the accuracy of fit and mechanical stability are worse. This study was aimed to evaluate the deviation and mechanical performance of fibre-reinforced CAD/CAM PC (FRPC) fabricated in a fully digital chairside workflow, compared to those of CPC. On 30 teeth, a PC preparation was conducted, and a conventional and digital post impression were taken with an intraoral scanner. Fifteen teeth each were treated with CPC and FRPC, respectively. The deviation was evaluated by superimposing the datasets of the digitalised stone models and digital post impressions. Decementation and root fracture during chewing simulation were analysed by microscopy and X-ray. Statistical analysis was performed by pairwise comparison and Kaplan-Meier analysis. The median deviation for the "coronal", "middle" and "apical" were 14.5, 18.0 and 113.7 μm, respectively. The pairwise comparison for "coronal"/"middle" showed no significance (p = 0.465), whereas that for "coronal"/"apical" and "middle"/"apical" showed highly significant differences (p < 0.001). After chewing simulation, five decementations and two root fractures were detected for CPC. For FRPC, neither decementation nor root fracture were documented. Within the limitations of this study, FRPC performed significantly better than CPC.