Dental Preparation Guides—From CAD to PRINT and CAM

Objectives: The aim of this study was to present and describe a digital workflow integrating Digital Smile Design (DSD) with computer-aided design/computer-aided manufacturing (CAD/CAM) and additive manufacturing technologies for the fabrication of dental preparation guides, focusing on workflow feasibility, design reproducibility, and clinical handling. Materials and Methods: A digital workflow was implemented using intraoral scanning and Exocad DentalCAD 3.1 Elefsina software to design dental preparation guides based on digitally planned restorations. Preparation margins, insertion paths, and minimal material thickness were defined virtually. The guides were fabricated using both subtractive (PMMA milling) and additive (stereolithographic-based 3D printing) manufacturing techniques. Post-processing included chemical cleaning, support removal, additional light curing, and manual finishing. The evaluation was qualitative and descriptive, based on visual inspection, workflow performance, and guide adaptation to printed models. Results: The proposed digital workflow was associated with consistent fabrication of preparation guides and predictable transfer of the virtual design to the manufactured guides. Digital planning facilitated clear visualization of preparation margins and insertion axes, supporting controlled and minimally invasive tooth preparation. The workflow demonstrated good reproducibility and efficient communication between clinician and dental technician. No quantitative measurements or statistical analyses were performed. Conclusions: Within the limitations of this qualitative feasibility study, the integration of DSD with CAD/CAM and 3D printing technologies represents a viable digital approach for designing and fabricating dental preparation guides. The workflow shows potential for improving predictability and communication in restorative dentistry.