{"id":246,"date":"2026-08-09T05:13:57","date_gmt":"2026-08-09T05:13:57","guid":{"rendered":"https:\/\/www.fullarchmasters.com\/articles\/digital-full-arch-workflow-steps"},"modified":"2026-08-09T05:13:57","modified_gmt":"2026-08-09T05:13:57","slug":"digital-full-arch-workflow-steps","status":"publish","type":"post","link":"https:\/\/www.fullarchmasters.com\/articles\/digital-full-arch-workflow-steps","title":{"rendered":"Digital Same-Day Full Arch Workflow: 7 Steps Explained"},"content":{"rendered":"<p><em>Written by: Ryan Dunlop, CEO and Founder of Full Arch Masters and graduate from the Harvard School of Dental Medicine<\/em><\/p>\n<h2 id=\"key-takeaways\">Key Takeaways<\/h2>\n<ul>\n<li>The FAM Method uses a seven-step, photogrammetry-first digital workflow to deliver a same-day, screw-retained full-arch prosthesis in 2\u20134 hours with one integrated team and platform.<\/li>\n<li>Accurate preoperative records, photogrammetry, and CBCT\u2013IOS merging create a precise 3D dataset that guides every planning, design, and delivery decision.<\/li>\n<li>Parallel execution, with lab technicians designing in exocad while the dentist operates, compresses chair time and removes second-day appointments.<\/li>\n<li>Immediate-load conversion, zirconia finishing, and FP1-specific scaling follow clear handoffs, quality checkpoints, and defined team roles so outcomes stay predictable as volume grows.<\/li>\n<li>Train your entire team on the complete FAM Method workflow at <a href=\"https:\/\/www.fullarchmasters.com\/\" target=\"_blank\">Full Arch Masters<\/a> and bring same-day full-arch delivery into your practice.<\/li>\n<\/ul>\n<h2>Seven FAM Method Steps for Same-Day Full-Arch Delivery<\/h2>\n<ol>\n<li><strong>Preoperative records and data acquisition<\/strong> (0:00\u20130:30)<\/li>\n<li><strong>Photogrammetry and intraoral scanning<\/strong> (0:30\u20131:00)<\/li>\n<li><strong>CBCT and digital treatment planning<\/strong> (concurrent with surgery prep)<\/li>\n<li><strong>exocad design<\/strong> (lab-side, parallel to surgery)<\/li>\n<li><strong>Immediate-load conversion<\/strong> (1:00\u20132:30)<\/li>\n<li><strong>Final zirconia design and finishing<\/strong> (post-healing phase)<\/li>\n<li><strong>FP1-specific design, team implementation, and workflow scaling<\/strong> (ongoing)<\/li>\n<\/ol>\n<p>Total chairside time for steps 1\u20135 is 2\u20134 hours. Steps 6 and 7 guide the transition to the definitive prosthesis and the systems that let a practice scale volume predictably.<\/p>\n<h2>Step 1: Preoperative Records and Data Capture<\/h2>\n<p><strong>Step 1 | 0:00\u20130:30 | Who: Surgical assistant + treatment coordinator<\/strong><\/p>\n<p>Accurate preoperative records give you the foundation for every digital decision that follows. A merged dataset that combines CBCT DICOM files with intraoral scan STL files produces a single 3D model with bone dimensions, soft-tissue positions, and mapped critical structures, including the maxillary sinus floors, inferior alveolar nerve, and mental foramina.<\/p>\n<ul>\n<li><strong>Full-arch intraoral scan (STL)<\/strong> is captured before any extractions to preserve tooth position and occlusal reference, which becomes the baseline for prosthetic design.<\/li>\n<li><strong>CBCT acquisition (DICOM)<\/strong> is taken with the patient in occlusion so radiopaque fiducial markers or remaining dentition can serve as registration landmarks when you merge with the IOS data.<\/li>\n<li><strong>Facial scan<\/strong> supplies lip support, smile line, and vertical dimension reference that CBCT and IOS cannot capture, which is especially critical in fully edentulous cases without tooth references.<\/li>\n<li><strong>Dataset merge and verification<\/strong> occurs in planning software, which aligns CBCT and IOS by matching anatomical landmarks, and cross-sectional views confirm registration accuracy before you hand off the file.<\/li>\n<li><strong>Handoff checkpoint<\/strong> happens when the surgical assistant confirms merged file integrity and transfers it to the treatment planning station before the patient enters the operatory.<\/li>\n<\/ul>\n<h2>Step 2: Photogrammetry and Intraoral Scanning<\/h2>\n<p><strong>Step 2 | 0:30\u20131:00 | Who: Surgical assistant (intraoral scan) + dentist (photogrammetry)<\/strong><\/p>\n<p>Photogrammetry serves as the accuracy engine of the FAM Method. Conventional intraoral scanners accumulate stitching errors across a full arch, and photogrammetry avoids that problem by using encoded scan bodies on implants to triangulate precise 3D implant positions, angles, and soft-tissue data in a single capture.<\/p>\n<ul>\n<li><strong>Scan body placement<\/strong> starts with coded scan bodies seated on multi-unit abutments immediately after implant placement.<\/li>\n<li><strong>Photogrammetry capture<\/strong> records implant positions with micron-level accuracy so the digital model reflects true implant locations.<\/li>\n<li><strong>Soft-tissue intraoral scan<\/strong> captures peri-implant gingival contours after scan body removal and merges them with photogrammetry data to create a unified 3D model.<\/li>\n<li><strong>Dataset transmission<\/strong> sends the merged STL to the lab station in real time so design can begin while surgery continues.<\/li>\n<li><strong>Quality checkpoint<\/strong> occurs when the dentist reviews the photogrammetry output and confirms complete implant registration before closing the surgical site.<\/li>\n<\/ul>\n<h2>Step 3: CBCT Merge and Digital Treatment Planning<\/h2>\n<p><strong>Step 3 | Concurrent with surgery prep | Who: Lab technician + dentist<\/strong><\/p>\n<p>Prosthetically driven planning starts with the tooth arrangement, then places implants to support the planned prosthesis. Virtual implant positions must respect bone volume, avoid the inferior alveolar nerve, mental foramina, sinus floor, and nasal cavity, and maintain acceptable screw-access channels and prosthetic space.<\/p>\n<ul>\n<li><strong>CBCT + IOS merge<\/strong> aligns DICOM and STL in planning software using anatomical landmarks or fiducial markers, and cross-sectional views verify alignment accuracy before you proceed.<\/li>\n<li><strong>Virtual implant placement<\/strong> positions implants for bone density (Misch Type I\u2013IV), antero-posterior spread, and prosthetic emergence that supports the planned tooth setup.<\/li>\n<li><strong>Primary stability decision<\/strong> uses insertion torque and ISQ to decide on immediate loading. ITI consensus guidelines recommend insertion torque &gt;35 Ncm or ISQ &gt;70 as a criterion for immediate loading in anterior single-tooth sites, and the FAM Method applies these thresholds across full-arch cases.<\/li>\n<li><strong>Surgical guide output<\/strong> creates a fully guided static guide that is 3D-printed in biocompatible resin, and fully guided surgery often produces lower angular deviations than freehand placement.<\/li>\n<li><strong>Handoff checkpoint<\/strong> occurs when the lab technician locks the planning file and exports design parameters to exocad before surgery begins.<\/li>\n<\/ul>\n<h2>Step 4: exocad Design for Provisional and Final Prostheses<\/h2>\n<p><strong>Step 4 | Parallel to surgery | Who: Lab technician<\/strong><\/p>\n<p>The lab technician designs in exocad while the dentist operates, which keeps the case on a 2\u20134 hour timeline. The same dataset supports both the immediate-load provisional and the final prosthesis framework.<\/p>\n<ul>\n<li><strong>Immediate-load provisional design<\/strong> imports photogrammetry-derived implant positions and references tooth arrangement against the preoperative facial scan and digital wax-up.<\/li>\n<li><strong>Occlusal scheme<\/strong> maintains 2 mm occlusal clearance in the molar region during the initial healing phase to protect implants.<\/li>\n<li><strong>Final prosthesis framework<\/strong> starts zirconia design from the same dataset and verifies screw-access channels for angulation and emergence.<\/li>\n<li><strong>File export<\/strong> queues STL files for 3D printing of the immediate-load provisional and milling of the final zirconia, and the lab technician confirms passive fit parameters before fabrication.<\/li>\n<li><strong>Quality checkpoint<\/strong> lets the dentist review the provisional design on screen before printing so occlusal or emergence adjustments happen digitally instead of chairside.<\/li>\n<\/ul>\n<p><a href=\"https:\/\/www.fullarchmasters.com\/\" target=\"_blank\"><strong>Master exocad design and the full FAM workflow at an upcoming Full Arch Masters course.<\/strong><\/a><\/p>\n<h2>Step 5: Chairside Immediate-Load Conversion<\/h2>\n<p><strong>Step 5 | 1:00\u20132:30 | Who: Dentist + surgical assistant<\/strong><\/p>\n<p>The immediate-load conversion turns a multi-visit process into a same-day experience. A 3D-printed PMMA provisional from Step 4 seats directly on the multi-unit abutments without luting, bite adjustment, or a physical model.<\/p>\n<ul>\n<li><strong>Provisional seating<\/strong> starts with a try-in of the printed provisional, confirmation of screw access, and verification of passive fit against photogrammetry data.<\/li>\n<li><strong>Occlusal verification<\/strong> checks bilateral contacts and anterior guidance and confirms that no heavy excursive contacts exist on the provisional.<\/li>\n<li><strong>Screw torque and access closure<\/strong> follow manufacturer torque specifications, and access holes are sealed with PTFE and composite.<\/li>\n<li><strong>Patient instructions<\/strong> cover soft diet, oral hygiene, and the follow-up timeline, which the treatment coordinator reviews before dismissal.<\/li>\n<li><strong>Quality checkpoint<\/strong> uses post-operative periapical radiographs to confirm accurate seating and stable connections across all implants before the patient leaves the chair.<\/li>\n<\/ul>\n<h2>Step 6: Final Zirconia Design, Finishing, and Delivery<\/h2>\n<p><strong>Step 6 | Post-healing phase | Who: Lab technician + dentist<\/strong><\/p>\n<p>The definitive zirconia prosthesis is fabricated after soft-tissue maturation, usually at the prosthetic release appointment. The photogrammetry dataset from surgery carries implant position data forward, so a new full-arch impression is not required.<\/p>\n<ul>\n<li><strong>Tissue maturation scan<\/strong> captures an intraoral scan at prosthetic release to document healed peri-implant contours and merges it with the original photogrammetry data.<\/li>\n<li><strong>Verification jig try-in<\/strong> uses a jig to confirm passive fit of the master cast before framework fabrication, and any discrepancy is resolved digitally before milling.<\/li>\n<li><strong>PMMA prototype evaluation<\/strong> checks esthetics, phonetics, occlusion, and vertical dimension, and both patient and dentist approve the prototype before zirconia milling.<\/li>\n<li><strong>Green-stage zirconia contouring<\/strong> shapes pre-sintered zirconia for emergence profile and surface texture, and MIYO ceramic layering adds characterization.<\/li>\n<li><strong>Final delivery and torque<\/strong> seats the definitive prosthesis, applies final torque, seals access holes, and confirms seating with post-delivery periapical radiographs.<\/li>\n<\/ul>\n<h2>Step 7: FP1 Design, Team Roles, and Scaling the Workflow<\/h2>\n<p><strong>Step 7 | Ongoing | Who: Full team<\/strong><\/p>\n<p>FP1 prosthetics require different decisions than FP2 and FP3, and they demand aligned systems across the team. When FP1 capability and the seven-step workflow are fully systematized, practices can move from a few arches per month to a predictable, higher volume.<\/p>\n<ul>\n<li><strong>FP1 case selection criteria<\/strong> review root banking, bone volume, and esthetic zone requirements at treatment planning, and apply FP1-specific exocad design parameters.<\/li>\n<li><strong>Team delegation map<\/strong> assigns each of the seven steps to a named role with clear entry and exit criteria so the dentist avoids non-billable tasks.<\/li>\n<li><strong>Checklist implementation<\/strong> standardizes room setup, records acquisition, photogrammetry, and handoffs so any trained assistant can execute without verbal instruction.<\/li>\n<li><strong>Workflow audit cadence<\/strong> reviews case timing and quality checkpoint data after each arch and resolves bottlenecks before the next case.<\/li>\n<li><strong>Scaling checkpoint<\/strong> targets five or more arches per month once the seven-step workflow runs without dentist intervention at Steps 1, 2, and 4.<\/li>\n<\/ul>\n<p><a href=\"https:\/\/www.fullarchmasters.com\/\" target=\"_blank\"><strong>Bring your full team to Full Arch Masters and operationalize the seven-step workflow together.<\/strong><\/a><\/p>\n<h2>What Breaks the FAM Method Workflow?<\/h2>\n<p>The following failure points cause most same-day full-arch delays and remakes, and each has a defined fix within the FAM Method.<\/p>\n<ol>\n<li><strong>Poor CBCT\u2013IOS registration<\/strong> creates incorrect implant positions in the surgical guide. <em>Fix:<\/em> Verify alignment in cross-sectional view using at least three matching anatomical landmarks before exporting the plan, and use radiopaque fiducial markers in edentulous cases.<\/li>\n<li><strong>Insufficient primary stability for immediate load<\/strong> appears when insertion torque falls below the ITI-recommended 35 Ncm threshold or ISQ drops below 60, which increases micromotion risk. <em>Fix:<\/em> Apply the FAM primary stability decision tree at placement, convert to a healing protocol when thresholds are not met, and schedule a second-stage provisional. <a href=\"https:\/\/pmc.ncbi.nlm.nih.gov\/articles\/PMC13115284\" target=\"_blank\" rel=\"noindex nofollow\">Implants below these thresholds can still achieve high survival rates under delayed loading.<\/a><\/li>\n<li><strong>Photogrammetry scan body contamination<\/strong> occurs when blood or fluid on encoded scan bodies introduces position error. <em>Fix:<\/em> Irrigate and dry each scan body before capture, and confirm all coded patterns are fully visible in the photogrammetry preview before accepting the scan.<\/li>\n<li><strong>Provisional occlusal interference<\/strong> arises when heavy excursive contacts on the immediate-load provisional generate micromotion. <em>Fix:<\/em> Verify the occlusal scheme in exocad before printing, and confirm bilateral contacts and anterior guidance chairside before torquing screws.<\/li>\n<li><strong>Undefined team handoffs<\/strong> push tasks back to the dentist and compress the schedule. <em>Fix:<\/em> Assign every step in the seven-step workflow to a specific role with a written entry criterion, exit criterion, and quality checkpoint before the first case runs.<\/li>\n<\/ol>\n<h2>Frequently Asked Questions<\/h2>\n<h3>How long does the full FAM Method workflow take from patient arrival to same-day prosthesis delivery?<\/h3>\n<p>The FAM Method delivers a screwed-in, same-day full-arch restoration in 2\u20134 hours from patient arrival. Steps 1\u20135, from preoperative records through immediate-load conversion, fit within that window when the team executes in parallel, with the lab technician designing in exocad while the dentist operates and the provisional printing while surgery is completed. Steps 6 and 7 manage the transition to the definitive zirconia prosthesis and workflow scaling, which occur across later appointments after soft-tissue maturation.<\/p>\n<h3>How many team members are needed to run the FAM Method same-day workflow?<\/h3>\n<p>The FAM Method relies on at least three aligned roles: the dentist, a trained surgical assistant, and a lab technician. A treatment coordinator serves as the fourth role and is essential for patient flow, post-operative instruction, and case scheduling. The workflow keeps the dentist focused on billable clinical tasks such as records oversight, photogrammetry oversight, surgery, and prosthesis delivery, while the assistant and lab technician execute Steps 1, 2, and 4 in parallel. Practices that train the full team on day one usually operationalize the workflow faster than those that send only the dentist.<\/p>\n<h3>How do you decide whether a patient qualifies for immediate loading on the day of surgery?<\/h3>\n<p>The FAM Method uses a primary stability decision tree at the time of implant placement, based on insertion torque and Implant Stability Quotient (ISQ). The FAM Method applies the ITI-recommended thresholds of &gt;35 Ncm insertion torque or ISQ &gt;70 when deciding on immediate loading. When the criterion is met, the immediate-load provisional proceeds. When it is not met because of bone quality, density classification, or anatomical limits, the protocol converts to a healing approach, the patient receives a transitional prosthesis, and a second-stage provisional follows osseointegration. The decision is made chairside, documented in the case record, and communicated to the lab technician before the provisional print starts.<\/p>\n<h3>When should photogrammetry be used instead of a conventional scan body approach for full-arch implant position capture?<\/h3>\n<p>The FAM Method prefers photogrammetry for all full-arch immediate-load cases. Conventional intraoral scanners accumulate stitching errors across a full arch, especially in edentulous cases without stable tooth surfaces to anchor scan frames. Photogrammetry avoids this by using encoded scan bodies to triangulate implant positions with micron-level accuracy in a single capture. A conventional scan body approach with a rigid splinted assembly remains an acceptable alternative when photogrammetry hardware is not available, but it requires extraoral scanning and additional verification steps that add time to the workflow.<\/p>\n<h3>How does the immediate-load provisional transition to the final zirconia prosthesis?<\/h3>\n<p>After a healing period that allows soft-tissue maturation, the patient returns for the prosthetic release appointment. The lab technician merges a new intraoral scan of the healed peri-implant contours with the original photogrammetry dataset, so no new full-arch impression is required. A verification jig is tried in over the implants to confirm passive fit before framework fabrication. A PMMA prototype is then evaluated for esthetics, phonetics, occlusion, and vertical dimension, and both patient and dentist approve the prototype before zirconia milling. Green-stage contouring and MIYO ceramic layering provide characterization and surface texture before final delivery and torque.<\/p>\n<h3>Does Full Arch Masters offer AGD PACE-approved continuing education credits?<\/h3>\n<p>Full Arch Masters is an AGD PACE-approved CE provider. The Flagship Course, Design and Finish Course, and Live Surgical Course each carry 32 continuing education credits. The full FAM Fellowship program, which bundles the three core courses plus a fourth course of the practice&#8217;s choice, delivers more than 90 CE hours across the complete curriculum. Every attendee receives CE credit documentation after course completion, which applies toward AGD Fellowship and Mastership requirements for eligible dentists.<\/p>\n<h2>Ready to Bring the FAM Method into Your Practice?<\/h2>\n<p>The seven-step FAM Method functions as a complete, repeatable operating system rather than a single technique. It covers every handoff, every quality checkpoint, and every team role from preoperative records through definitive zirconia delivery. Alumni report adding more than $1M per year in practice revenue after adopting the workflow, and every attendee joins a community of hundreds of FAM-trained dentists, lab technicians, and team members for ongoing case support.<\/p>\n<p><a href=\"https:\/\/www.fullarchmasters.com\/\" target=\"_blank\"><strong>Register for an upcoming Full Arch Masters course and implement the FAM Method in your practice.<\/strong><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Learn the 7-step FAM Method digital same-day full arch workflow. Full Arch Masters trains your team to deliver screw-retained arches in 2\u20134 hours.<\/p>\n","protected":false},"author":119,"featured_media":245,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[1],"tags":[],"class_list":["post-246","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/posts\/246","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/types\/post"}],"replies":[{"embeddable":true,"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/comments?post=246"}],"version-history":[{"count":0,"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/posts\/246\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/media\/245"}],"wp:attachment":[{"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/media?parent=246"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/categories?post=246"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.fullarchmasters.com\/articles\/wp-json\/wp\/v2\/tags?post=246"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}