Split into two: Quick, simple and precise
The current DentalCAD 3.3 Chemnitz release from exocad introduces a new split denture workflow, available in the Bar Module. Users can now design the bar and suprastructure in one single, streamlined workflow. For those working with All-on-X full-arch bridges, the software now splits the design into two precisely matching components. How does it work? exocad application specialist and dental technician Patricia Moreno Gil demonstrates the new workflow and shares some practical tips for users.
The split denture workflow is now a routine part of many labs’ daily work. It is used for both full-arch rehabilitations and partial restorations, including bridges with multiple pontics. With the new DentalCAD 3.3 Chemnitz release, the split denture process is now significantly simpler. One key advantage: the new features are integrated directly into DentalDB. This allows users to work with the familiar Bar Module and Implant Module.
Simple in the hands of every user
The split denture feature can be handled by any software user, from beginners to experienced dental technicians. Thanks to the guided wizard workflow, the entire process is highly intuitive. The design process follows a backward-planning approach, beginning with the final restoration’s design. Users can then segment the design and generate the substructure by applying the appropriate adaptation parameters to both components.
Here is how it works
First, you set up the case in DentalDB, as well as the parameters and options for the suprastructure. Users will already see the new option “Design bar?” in this early workflow stage. By clicking “Yes, in wizard” (Fig. 1),
Fig. 1: “Design bar?” option in DentalDB
They will automatically be guided into the split denture workflow in the later design process. If users choose not to enable the workflow initially, they can still activate it later using the “Design bar” option in expert mode. When setting up the case in DentalDB, users can also already select the parameters for the bar design, such as the bar material. Other parameters, like “Minimum thickness” or “Gap width of cement,” can be defined here and still be modified later in the workflow. All parameters and options set at this stage can be saved, making it more efficient to manage future cases with the same indication.
After designing the suprastructure, which includes the teeth and gingiva, users proceed with bar design. The software offers a variety of options. New in this release is the “Split” tab in the bar design step (Fig. 2).
Fig. 2: “Split” tab with different options to adjust the bar
Users only need to add and modify the split curve (Fig. 3),
Fig. 3: Add/modify split curve
which defines where the structure will be separated. They can then choose from various bar adapting options (Fig. 4).
Fig. 4: Bar adapting options
Afterwards, users can control and adjust the parameters that influence the shape of and the spacing between the two components (Fig. 5).
Fig. 5: Control of the different parameters that affect the shape and fit.
By clicking “Apply,” the software automatically separates the bar from the suprastructure within seconds (Fig. 6).
Fig. 6: Preview how the software separates the bar from the suprastructure depending on the selected option.
Users can then free-form the bar and the adapted suprastructure (Fig. 7&8).
Fig. 7: Free-forming the bar makes it possible to keep selected surfaces fixed.
Fig. 8: Free-forming the suprastructure
Advantages for users
Precise fit: The bar and its suprastructure fit precisely together. This can be easily verified in the split denture workflow, as DentalCAD 3.3 Chemnitz provides various parameters for dividing the structure. These options allow for more refined adjustments and improved passivity.
Benefits of this type of restoration: Combining structures helps keep the esthetic advantages of zirconia and porcelain by adding the stability and passive fit of a metal bar to reduce stress on the zirconia and porcelain.
Reliable esthetics with a wide range of materials: Designing the bar as part of the split denture workflow helps to reinforce and stabilize the structure, without compromising esthetics. This is possible because we control the parameters for both the bar and the suprastructure within the same workflow, allowing us to fine-tune and adjust them as needed. The split denture workflow enables users to work with a wide range of materials, from composites and ceramic composites to zirconia. The same is true for the substructure, which can be made of metal (e.g., titanium) or other materials such as PEEK, particularly in metal-free restorations.
Suitable for existing restorations
Good to know: The DentalCAD split denture workflow can also be used to reinforce existing restorations. Users can import older restorations into the software and use the segmentation process to divide them into two parts (Fig. 9).
Fig. 9: Bar and suprastructure merged as two individual parts.
In short
The split denture workflow is highly efficient, precise and fully integrated in the exocad environment, making it easy to combine with other types of restorations—for example, cemented crowns and bridges.
Patricia’s personal tip
I encourage users to try the new split denture workflow in DentalCAD because it’s very modern and cutting-edge. It offers many advantages and can be applied not only to implant-based full-arch prostheses but also improves the stability of structures by reinforcing them without compromising esthetics. The exocad wiki page Bar Module Split Bar – exocad explains every workflow step and parameter in detail. I definitely recommend taking a look. Users can always access the page directly in the software by clicking the question mark icon in the wizard at the step where the splitting is performed. In general, exocad offers many resources for learning: the wiki page, our YouTube channel and personalized training. Just go for it.
About Patricia, Application Specialist at exocad
Patricia has been working at exocad since 2021, but her journey with exocad software began in 2010 as a dental technician in a lab. Today, she is proud to contribute to the team’s ongoing innovations. She provides third-level support and training to exocad resellers and technology partners, with a particular passion for end-user training. Patricia thrives on working directly with lab and clinic users, sharing practical insights, demonstrating workflows in exocad, and showing how digital processes can be applied in everyday practice.