Toronto bridge in Fiberglass and Composite material

Hi everyone,
my name is Francesco Napolitano, a  Dental Technician, and DGSHAPE customer for some time now. I am excited to share this fantastic project and I would like to thank DGSHAPE for this great opportunity. I am convinced that sharing knowledge, continually updating, and being able to form a team leads to exceptional results.  Digital technology is helping us achieve this, but it is always the people, intuition, and continuous learning that makes the difference.   When searching for solutions, the Surgery/Laboratory collaboration is a winning combination!   I believe that for a surgery to provide its patient with fast solutions to problems that often create anxiety, is a great result! And, the fact that we laboratories can help our referral surgeries is equally significant. This encourages us, together with our passion, to always do our best. Digital knowledge also helps us to come up with new concepts and processes.


Let’s start by scanning the 2 arches in the articulator, and from the position of the implants in the lower maxillary.

Having done this, we can start to position the anatomies in the same position as the final work, so we have the correct position of each individual die on our primary structure.



Once the anatomies are in position, we use the THIMBLE function to reduce our Anatomies. All this is done exclusively with Exocad and without the use of other software or tools.

Once our anatomies have been reduced,  we make a slight reduction of our finished gum, which will be covered with a pink composite material at the end. We generate the final STL file that we will dry mill in fibreglass, using a DWX 5 axis with specific strategies for this kind of material created in HYPERDENT. The DGSHAPE machines are compact, precise and versatile, and an ideal aid to in-house processings even for complex jobs like this.



Primary structure in fibreglass glued on TiBase

Once our primary fibreglass structure has been milled, we cement it onto our TI-BASES and subsequently check the fit, which should be completely passive on our model.

Once the precision and passivity of our structure has been checked, we use the same project as before, duplicating it, showing the same scans made previously, modifying it by inserting the anatomic crowns in the worksheet, from 36 to 46.

And we will only check the section “screw fixing” in the implants zone. So we can design the anatomical crowns with a hole for the screw that will allow us to create screw retained crowns. By doing this, we should only have to scan the lower model, and combine it with the previous files, marking reference points on the plaster model.  This merging operation proves to be very simple given that we are working on the same model and therefore we have a great deal of data to perform a correct coupling. When I perform jobs of this kind, I always prefer to make a double scan, and not plan the primary and secondary in one go. And you again find me managing the fit and milling parameters individually, which is how I generally do these processes. Furthermore, I believe that performing a double scan gives greater precision and is more manageable, being able to better control tailored closure lines and cement gaps. 

Once the nesting has been done with the HYPERDENT

It will all be dry milled with a DWX 5 axis DGSHAPE mill, with specific strategies for this kind of material created in HYPERDENT.



In this case, multi-layer blocks have been selected in order to have a gradual dentin-enamel colouring given that we are working in monolithic crowns, and so, without the addition of composite portions

Once the milling is complete, the next stage is fitting the individual crowns on the primary structure. Once the M/D contact points have been checked, sand-blasting begins inside the crowns and on the whole surface of the primary structure to start the gluing stages between the two parts.  Once the gluing stage is completed, freehand layering begins of the pink gingiva, this too is done in composite material.





Once the layering is complete, the next stage is the finishing touch and final polish, with an adequate check made of the cleansing areas between the implants, mucosa and the Toronto bridge.



As it works toward future business expansion, DGSHAPE is promoting activities to reach the mid-term objectives of “strengthening the ability to support new dental materials,” “acceleration of global expansion” and “developing high value-added solutions for the dental industry” In the dental market, an important requirement for DGSHAPE is to support new materials. We, therefore, pay close attention to the new product offerings of material manufacturers and the needs of patients and dental clinics in order to offer optimal processing methods as quickly as possible.


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