The Proof Is in the Final
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The Proof Is in the Final

The Proof Is in the Final

Discover a cutting-edge full-arch workflow that delivers custom-milled titanium bars and zirconia superstructures within 24 hours of implant surgery

 

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RYAN DUNLOP, DMD

Dr. Dunlop is the CEO and Founder of Full Arch Masters, an educational community dedicated to helping dentists and lab technicians elevate their skills in full-arch implant restorations. After graduating from the Harvard School of Dental Medicine in 2006, he spent 2 years working for the Veterans Hospital in New York City. Since then, he has become a nationally and internationally recognized expert in full-arch and full-mouth implant reconstruction. He pioneered the modern fully digital workflow for full-arch reconstructions, which allows patients to get same-day teeth using modern technology like 3D printing and photogrammetry. Dr. Dunlop has lectured across the globe and taught thousands of dentists and oral surgeons how to obtain optimal outcomes for their patients.

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Dr. Ryan Dunlop, founder of Full Arch Masters and owner of a busy implant practice in Fresno, CA, has long championed in-house milling for his full-arch restorations. After experimenting with several milling systems, he turned to Axsys Dental Solutions’ Versamill, and the results have been nothing short of transformative.

 

“Axsys has really accelerated protocols in my clinic and lab with high-speed, predictable zirconia milling, as well as expert CAD/CAM support,” Dr. Dunlop said. “We can have full arches milled in around 90 minutes or less, which is much faster than most competitors, and we’re milling metal at a high rate with a very high degree of predictability.”

 

A Break from the Traditional

 

But the most exciting innovation to come out of the Versamill is what Dr. Dunlop calls the “bulletproof final.” In traditional full-arch implant dentistry, metal frameworks and zirconia superstructures are designed, milled, sintered, and fitted in separate steps—often spanning several days. With bulletproof finals, one design file is split into 2 milling jobs.

 

“Now, we can put these 2 materials together very reliably and predictably into what I like to call the bulletproof final,” Dr. Dunlop said. 

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The workflow connects a custom-milled, high-precision titanium framework to the dental implant, which has a zirconia superstructure on top of it.

 

“You can have one mill running the metal frame-work, which takes about an hour and a half to 2 hours, and the other mill simultaneously milling the zirconia superstructure, which takes about the same time,” he said. “At the end of a 2-hour milling cycle, you have both products done at the same time.”

 

Speed Up Sintering

 

While conventional zirconia sintering can take up to 12 hours, Dr. Dunlop noted that a newly developed material and oven with a special temperature will allow zirconia to be sintered in just 2 hours.

 

“Now, you have a 2-hour precision mill, 2-hour sinter, and you can actually get this entire project milled, sintered, and finished in a single business day,” Dr. Dunlop said. “That provides a tremendous advantage to labs and in-house labs. They can get these projects done in a timely manner for patients who might literally be waiting for the restoration.”

 

Ultimately, by combining Axsys’ expertise and high-speed Versamills with the bulletproof final workflow, labs and dental practices can now deliver full-arch implant restorations—from surgery to permanent prosthesis—in less than 24 hours. 

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