VIDEO: Scan-Design-Print-Deliver With iTero Lumina™ and SprintRay Midas

This video shows the full digital workflow with replacing old amalgams to a 3D-printed onlay. We are using the iTero Lumina™ and the SprintRay Midas for this case.

Video Summary

Phil Leinberger from Voxel Dental showcases a complete digital restorative workflow featuring Dr. Dave Christensen, a digital dentistry expert.

The case walks through replacing old amalgams with a 3D-printed onlay, leveraging advanced technologies such as iTero Lumina intraoral scanning, ExoCAD design, and SprintRay Midas 3D printing — with Phil himself as the patient.

Step 1: Digital Case Planning & Initial Scans

Dr. Christensen begins by reviewing clinical photos revealing fractures on the distal marginal ridge and buccal aspect, requiring a stronger restoration.

• iTero Lumina Scanner is used to capture pre-prep scans of the upper, lower, and bite records.

• Integrated clinical photo capture enables documentation directly within the scan, streamlining insurance claims and patient education.

Step 2: Tooth Preparation & Post-Prep Scans

After local anesthesia, tooth preparation and contouring are completed.

• A post-prep scan is captured using the iTero Lumina.

• The scanner’s built-in photo tools allow real-time visualization of interproximal caries and clinical surfaces, eliminating the need for a separate camera.

Step 3: Digital Design in ExoCAD

The scanned STL files are exported to ExoCAD for onlay design:

• The restoration is digitally designed with precise occlusal adjustments.

• iTero’s integrated design suite can alternatively be used for chairside cases, sending files directly to the printer without third-party CAD software.

Step 4: 3D Printing the Onlay with SprintRay Midas

The onlay is printed using SprintRay’s MIDAS resin printer:

• Crown HT Resin is selected — a high-translucency material with 63% ceramic filler for superior esthetics and strength.

• The software automatically generates supports, but customization is possible.

• MIDAS’s triple-cartridge system allows up to three simultaneous prints, with an average print time of ~7.5 minutes.

Step 5: Post-Processing the Print

After printing, the restoration undergoes a detailed post-processing workflow:

• Resin cleaning: Excess uncured resin is removed using air, a micro-brush, and minimal alcohol (to protect material integrity).

• NanoCure unit: A 10-minute cure ensures optimal strength and biocompatibility.

• "Candy coating" glaze: A thin resin layer is light-cured under glycerin to remove the oxygen inhibition layer for a smooth, glossy finish.

• Light sandblasting refreshes the bonding surface for proper cement adhesion.

Step 6: Bonding & Final Cementation

The onlay is seated using a meticulous bonding protocol:

1. Surface conditioning with MonoBond silane.

2. Universal adhesive application and light-curing.

3. Resin cementation with Variolink, ensuring strong retention.

4. Contact verification, cement cleanup, and final polishing.

The final restoration demonstrates seamless margins, natural translucency, and excellent occlusal fit.

Key Takeaways for Dentists

• End-to-End Digital Workflow: Combining iTero, ExoCAD, and SprintRay MIDAS delivers highly accurate, efficient restorations.

• Faster Turnaround: Single-visit chairside solutions with ~7–10 minute prints.

• Material Advancements: High-translucency ceramic-filled resins improve esthetics and longevity.

• Patient Experience: Intraoral photo integration and real-time visualization boost case acceptance.