Onlay restoration with direct metal laser sintering technology: A digital approach to prosthetic repair.

Abstract Introduction: Full-mouth rehabilitation aims to restore function, aesthetics, and occlusion in patients with extensive dental wear, damage, or previous prosthetic failure. The selection of materials and techniques significantly influences the long-term success of the prosthesis. Case characteristics: A patient reported to the department with chief complaints of a fractured porcelain-fused-to-metal (PFM) bridge. After evaluating the dislodged prosthesis, an intraoral scan of the existing condition was performed. A digital workflow was utilized to design a new onlay restoration. A Direct Metal Laser Sintering (DMLS) metal framework was fabricated and tried in the patient's mouth, followed by PFM layering. The final prosthesis was cemented using resin cement and occlusion was carefully adjusted. Conclusion: The integration of digital dentistry and DMLS technology provides a precise and efficient approach to rehabilitate prosthetic failures. This case highlights the importance of digital scanning, CAD-CAM designing, and metal laser sintering in achieving optimal prosthetic outcomes.