Designing and milling a full arch in zirconia over titanium t-base or custom abutments using exocad software involves a meticulous digital workflow. Here's a detailed description of the process:

Digital Design:

1. Patient Assessment:

   • Begin with a comprehensive assessment of the patient's oral health, including scans or impressions for a digital model.

2. Data Import into exocad:

   • Import the digital scans or impressions into exocad software to create a virtual model of the patient's dental anatomy.

3. Titanium T-Base or Custom Abutment Integration:

   • Integrate virtual titanium t-base or custom abutments into the design, ensuring proper support for the zirconia full arch.
   • Verify the alignment and fit of the titanium components within the digital model.

4. Anatomical Design of Zirconia Arch:

   • Design the anatomical shape of the zirconia full arch, taking into account the patient's natural tooth anatomy and aesthetic preferences.
   • Ensure proper contouring and alignment with the underlying titanium t-base or custom abutments.

5. Functional Considerations:

   • Optimize occlusion and functional aspects, considering both natural teeth and implant-supported regions.
   • Verify proper articulation during various jaw movements.

6. Aesthetic Customization:

   • Customize the aesthetics of the zirconia restoration, including shade, texture, and translucency.
   • Achieve a natural appearance that blends seamlessly with the patient's remaining dentition.

7. Margins and Fit:

   • Define precise margins for both the zirconia and titanium components to ensure a snug fit.
   • Confirm the fit within the patient's oral anatomy, addressing any issues related to gaps or misalignment.

8. CAD Tools and Features:

   • Utilize exocad's CAD tools for detailed design modifications and adjustments.
   • Implement features specific to implant-supported restorations and titanium components.

9. Quality Control:

   • Conduct a thorough review of the digital design, checking for accuracy, fit, and overall satisfaction with the aesthetics.
   • Collaborate with dental professionals for feedback and adjustments if necessary.

Digital Milling:

11. Exporting Design Files:

    • Export the finalized digital design files from exocad in a compatible format (e.g., STL) for the milling machine.

12. Milling Machine Setup:

    • Prepare the milling machine for the specific materials used (zirconia and titanium).
    • Install appropriate milling burs and calibrate the machine.

13. Material Loading:

    • Load zirconia and titanium blanks into the milling machine, ensuring they match the specifications of the digital design.

14. Milling Titanium Components:

    • Begin the milling process by fabricating the titanium t-base or custom abutments with precision, adhering to the digital design specifications.

15. Quality Control for Titanium Components:

    • Inspect the milled titanium components for accuracy, surface finish, and overall quality.
    • Ensure dimensions align with the digital design.

16. Milling Zirconia Full Arch:

    • Proceed with milling the zirconia full arch, taking into account the previously milled titanium components.
    • Use milling strategies that optimize efficiency and accuracy.

17. Quality Control for Zirconia Full Arch:

    • Inspect the milled zirconia full arch for accuracy, anatomy, and overall quality.
    • Verify a precise fit with the titanium t-base or custom abutments.

18. Post-Milling Processes:

    • Perform any necessary post-milling processes, such as polishing, to achieve the desired final appearance.

19. Assembly of Titanium Components and Zirconia Arch:

    • Carefully assemble the milled zirconia full arch onto the previously milled titanium t-base or custom abutments, ensuring a secure and precise fit.
    • Verify the alignment and connection between the zirconia and titanium components.

20. Final Quality Check:

    • Conduct a final quality check to ensure that both the zirconia full arch and titanium components meet the required standards.
    • Address any issues identified during the quality check.

21. Delivery to the Dental Professional:

    • Package the milled zirconia restoration and titanium components securely for delivery to the dental professional for patient placement.

This detailed digital design and milling process, when executed with precision and attention to detail, result in a high-quality full arch restoration in zirconia over titanium t-base or custom abutments. Collaboration with skilled professionals throughout the workflow ensures the success of the final prosthetic restoration.