The milling process for a full arch in zirconia over a titanium t-base or titanium custom abutments, designed using exocad software, involves precise steps to ensure the creation of a high-quality dental restoration. Here's a detailed description of the milling phase:

Digital Design Verification:

1. Review Design Files:

   • Begin by verifying the accuracy and completeness of the digital design files generated in the previous design phase using exocad software.

2. Export Design Files:

   • Export the finalized digital design files, typically in STL format, from exocad for use in the milling machine.

Milling Machine Setup:

3. Prepare Milling Machine:

   • Set up the milling machine, ensuring it is calibrated and ready for the specific materials (zirconia and titanium) used in the restoration.

4. Install Milling Burs:

   • Install appropriate milling burs in the machine, considering the materials and the complexity of the restoration design.

Material Loading:

5. Load Zirconia and Titanium Blanks:
   • Load zirconia and titanium blanks into the milling machine, ensuring they match the specifications of the digital design.

Milling Titanium T-Base or Custom Abutments:

6. Milling Titanium Components:

   • Initiate the milling process to fabricate the titanium t-base or custom abutments with precision, following the digital design specifications.

7. Quality Control for Titanium Components:

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

Milling Zirconia Full Arch:

8. Set Milling Parameters:

   • Adjust milling parameters on the machine to match the characteristics of zirconia and the complexity of the full arch design.

9. Initiate Zirconia Milling:

   • Start the milling process for the zirconia full arch, taking into account the previously milled titanium components.

10. Optimize Milling Strategies:

    • Utilize milling strategies that optimize efficiency and accuracy in shaping the zirconia restoration.

11. Quality Control for Zirconia Full Arch:

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

Post-Milling Processes:

12. Deburring and Polishing:

    • Perform deburring to remove any rough edges from both the milled zirconia and titanium components.
    • Optionally, polish the surfaces for a smoother finish.

13. Final Quality Check:

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

Assembly and Delivery:

14. Assemble Components:

    • 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.

15. Final Quality Assurance:

    • Perform a final quality assurance check to ensure the overall fit, aesthetics, and functionality of the assembled restoration.

16. Delivery to the Dental Professional:

    • Package the completed restoration securely for delivery to the dental professional for patient placement.

This detailed milling process, when executed with precision and attention to detail, results in a high-quality full arch restoration in zirconia over a titanium t-base or titanium custom abutments. Collaboration with skilled technicians and adherence to design specifications are crucial for the successful fabrication of the dental prosthetic.