Full arch implant-supported restorations have become one of the most transformative procedures in modern dentistry — and digital workflows are making them more predictable, efficient, and accurate than ever before. Whether you're a dental lab processing your first full arch case or a seasoned clinician looking to streamline your process, having a clear, repeatable workflow is everything.
At Alien Milling Technologies, we've refined our digital full arch workflow to guide you through every stage — from initial records to final delivery — with clear decision points along the way. In this post, we'll walk through the entire process so you know exactly what to expect, what to order, and when.
Why Go Digital for Full Arch Cases?
Traditional full arch workflows involve stone casts, manual bite registrations, and a lot of back-and-forth between the chair and the lab. Digital workflows cut through that complexity. Intraoral scanners capture implant positions with high accuracy, CAD/CAM software enables virtual try-ins and design iterations, and 3D printing allows for rapid prototyping — all before committing to the final restoration.
The result? Fewer appointments, faster turnaround, better-fitting prostheses, and happier patients.
Stage 1: Initial Records (Visit 1)
Every full arch case starts with capturing the right data. For a single arch case — let's use the upper arch as our example — you'll need three things:
Scan the upper gums (the edentulous arch) to capture the tissue contours. This gives the designer the foundation for the prosthesis.
Scan the lower teeth or the existing denture while it's seated in the mouth. This establishes the opposing occlusion that the final restoration will articulate against.
Order a bite registration. This is critical — it establishes vertical dimension and ensures proper articulation between the upper and lower arches. We recommend the Alien Bite Block / Wax Rim, which is a wax rim bite block specifically designed for full arch implant cases. It ships with 3D printed models of your upper and lower arches, which you'll use again in Stage 2.
With these three records captured, you've laid the groundwork for the entire case.
Stage 2: Bite Capture & Design Submission (Visit 2)
This is where the case really takes shape. Stage 2 involves three distinct phases: in-office bite capture, extraoral scanning, and intra-oral scanning.
In-Office Steps
Start by placing the fabricated bite rim (from your Stage 1 order) in the upper arch. Have the patient bite down naturally and record the bite. This captures the vertical dimension of occlusion in a real-world setting — not just on an articulator.
Extraoral Scanning
Next, take the recorded bite and mount it onto the upper 3D printed model that was provided with your wax rim order. Occlude it with the 3D printed lower arch, and scan the occluded arches outside of the mouth. This extraoral scan gives you a clean, artifact-free capture of how the arches relate to each other.
Intra-Oral Scanning
Now it's time to capture implant positions. Install the MUA abutments, then place either MUA Scan Bodies or Photogrammetry Scan Bodies onto the abutments to capture precise implant placements. With the scan bodies in place, scan the upper arch intra-orally.
For MUA Scan Bodies, we carry the DESS MUA Scan Bodies, which provide reliable, accurate implant position capture.
A note on scan accuracy: If you're using an intra-oral scanner (as opposed to photogrammetry), consider ordering a Verification Jig. Intra-oral scans can sometimes overstitch across the arch, leading to small but clinically significant errors in implant positioning. A verification jig lets you confirm accuracy before moving forward. If you're using photogrammetry, this step isn't necessary — photogrammetry captures implant positions independently, so overstitching isn't a concern.
Choose Your Path: Design Submission
With all your scans captured — bite, upper scan body file, and lower scan — it's time to submit for design. Here's where the workflow forks depending on your setup:
If you have a 3D printer: Order a CAD Design Only from Alien Milling. Upload your bite scan, upper scan body file, and lower scan. We'll design the try-in and send you back a printable STL file that you can fabricate in-house. This is the fastest route — you control the printing timeline.
If you don't have a 3D printer: Order an Alien PMMA Full Arch Hybrid try-in. Upload the same three files, and we'll design, fabricate, and ship the PMMA try-in prosthesis to you. No printer required — we handle everything.
Stage 3: Try-In Appointment (Visit 3)
This is the moment of truth. Seat the try-in — whether you printed it in-house or received it from us — and evaluate:
- Esthetics: Do the teeth look natural? Is the shade appropriate?
- Phonetics: Can the patient speak clearly with the prosthesis seated?
- Midline: Is it centered and symmetrical?
- Occlusion: Are the contacts balanced and even?
- Vertical Dimension of Occlusion (VDO): Is the bite height correct?
If Everything Looks Good
Order your Alien Full Arch Hybrid (Final) and upload the same approved STL file. You can also select "From Diagnostic Wax Up or PMMA" and enter your PMMA Try-In or Design Order Number to avoid paying re-design fees. Then proceed directly to Stage 4 for delivery.
If Adjustments Are Needed
No problem — adjustments are a normal part of the process. Adjust the try-in intra-orally to correct any issues, then scan the adjusted full arch try-in. From there, you have two options:
Print in-house: Order a new CAD Design with the updated scan and print the revised try-in on your 3D printer.
Have us fabricate it: Order another Alien PMMA Full Arch Hybrid and we'll design and ship the updated try-in.
Repeat this stage as needed until the try-in is fully approved. Most cases require one, maybe two iterations before everything is dialed in.
Stage 4: Delivery Appointment (Visit 4)
Once your try-in has been approved, it's time to order the final prosthesis. You have two options depending on the clinical needs of the case:
Alien Full Arch Hybrid Zirconia — Our standard full arch final, milled from Alien HT Zirconia rated at 1,200 MPa. This is a strong, esthetic, and durable solution for most full arch cases. Browse Zirconia Full Arch options →
Alien iBar with Titanium Support — For cases that demand maximum strength and passive fit, the iBar features a milled titanium bar substructure with zirconia layered on top. This is the gold standard for long-term durability. Browse iBar Collection →
At the delivery appointment, seat the final prosthesis and verify fit, occlusion, and esthetics one last time before sending the patient home with their new smile.
Tips for Success
A few things to keep in mind throughout the workflow:
Ensure scan bodies are fully seated before scanning. A scan body that's even slightly off-axis will introduce error into the implant position data — and that error compounds across a full arch.
Always verify occlusion prior to submission. Check the bite registration against the patient's natural bite before uploading files. It's much easier to catch a discrepancy now than after the design is complete.
Label your files clearly. When uploading, make sure each file is clearly identified — Upper, Lower, Bite, Scan Bodies. This prevents mix-ups and ensures the design team has everything they need to start right away.
Maintain consistent vertical dimension throughout the workflow. From the initial bite registration through the try-in and into the final, VDO should remain stable. Any changes between stages can throw off the entire case.
See the Full Interactive Workflow
We've built an interactive, step-by-step version of this workflow that lets you expand each stage, choose your path at decision points, and link directly to the products you need at each step. It's designed to be a quick reference you can come back to on every case.
👉 View the Interactive Digital Full Arch Workflow →
Have questions about any stage of the process? Our team is available Monday through Friday, 8am–4:30pm PST. Call us at 844-ZIRCONIA or reach out through our Contact page. We're here to help you deliver predictable, high-quality full arch restorations — every time.