One of the most common questions from both patients and professionals entering the dental field is: what materials are dental prostheses made of? The answer is not straightforward, as material selection depends on the type of restoration, its location in the mouth, aesthetic and functional requirements, and the available budget. In this article, we review the most widely used dental prosthesis materials, how digital technology has transformed their processing, and what role a lab management platform plays in controlling these workflows.
Zirconia has become the flagship material of modern prosthetic dentistry. Its combination of exceptional mechanical strength (between 900 and 1200 MPa flexural strength) and natural aesthetics makes it the preferred choice for crowns, bridges, and implant-supported frameworks.
Different grades of zirconia exist based on translucency. High-translucency (HT) zirconia is used for monolithic crowns in the anterior region, where aesthetics take priority. High-strength zirconia is reserved for posterior bridges with multiple pontics, where masticatory load is greatest. Manufacturers like Ivoclar (IPS e.max ZirCAD), 3M (Lava), and Kuraray Noritake offer discs in multiple shades and translucency levels.
Zirconia processing is performed exclusively through CAD/CAM milling. The pre-sintered zirconia disc is milled in a 5-axis CNC machine and subsequently sintered in a furnace at temperatures between 1450 °C and 1550 °C. This sintering process shrinks the piece approximately 20-25% from the milled size, which the design software compensates for automatically.
Lithium disilicate (marketed primarily as IPS e.max Press and IPS e.max CAD by Ivoclar) is the material of choice when maximum aesthetics are required in single-unit restorations. Its translucency and ability to mimic natural enamel make it ideal for veneers, inlays, onlays, and anterior crowns.
With a flexural strength of approximately 400-530 MPa, lithium disilicate is less resistant than zirconia but significantly more aesthetic at reduced thicknesses. It can be processed both by pressing technique (injection over lost wax) and by CAD/CAM milling. In the CAD version, the block is milled in a partially crystallized state (bluish colour) and then crystallized in a furnace at 840 °C, at which point it acquires its final colour and translucency.
Cobalt-chrome (CoCr) alloys remain fundamental in dental prosthesis manufacturing, particularly for removable partial denture frameworks (skeletal prostheses), metal-ceramic bridges, and implant bars. Their high mechanical strength, biocompatibility, and relatively low cost keep them relevant despite advances in ceramic materials.
Traditionally manufactured by casting (lost-wax technique), they are now predominantly processed by CNC milling or, increasingly, by 3D printing through selective laser melting (SLM/DMLS). Additive metal manufacturing enables geometries impossible to achieve by casting and significantly reduces material waste.
PMMA is a thermoplastic polymer widely used for provisional prostheses, complete removable dentures, and as a trial material in complex rehabilitations. Its ease of processing, low cost, and acceptable aesthetics make it a versatile material in the dental laboratory.
In the digital workflow, PMMA is milled from pre-polymerized discs in CNC milling machines. These discs offer superior mechanical properties compared to manually polymerized PMMA, as they are manufactured under industrial pressure and temperature conditions. It can also be 3D printed using DLP or SLA technology with resins specifically formulated for provisionals.
Milled PMMA is especially useful for long-term provisionals in implant cases, where the patient may wear the provisional prosthesis for months while osseointegration completes. Its wear resistance and colour stability are superior to those of chairside-fabricated provisionals.
Laboratory composites and ceramic-polymer hybrid materials (such as Vita Enamic or Lava Ultimate) occupy an interesting niche between pure ceramics and polymers. They combine the aesthetics of ceramics with the resilience of polymers, resulting in materials that better absorb impact forces and are gentler on the opposing tooth.
These materials are processed exclusively by CAD/CAM milling and are indicated for inlays, onlays, single crowns, and veneers in situations where biomechanical behaviour similar to natural enamel is desired. Their modulus of elasticity, closer to that of dentin than zirconia, reduces the risk of abutment tooth fracture.
Titanium is the reference material for dental implants and implant-supported prosthetic components (abutments, bars, frameworks). Its exceptional biocompatibility, corrosion resistance, and osseointegration capacity make it irreplaceable in implantology.
In the dental laboratory, titanium is used to mill custom abutments, retention bars, and implant bridge frameworks. Titanium milling requires robust CNC machines with abundant cooling, as titanium generates significant heat during machining. Some laboratories also manufacture titanium frameworks by 3D printing (SLM), although this technology is still maturing for dental applications.
The digital revolution has radically changed how dental prosthesis materials are processed. The CAD/CAM workflow (computer-aided design / computer-aided manufacturing) enables designing restorations with micrometric precision and manufacturing them in an automated fashion, reducing human variability and improving consistency.
The process begins with a digital impression (intraoral scanner) or scanning of a physical model. The technician designs the restoration in specialized CAD software, defining the anatomy, occlusal contacts, margins, and material thickness. The design is sent to a CNC milling machine or 3D printer that fabricates the piece with sub-millimetre precision.
New technologies in dentistry continue to expand possibilities: artificial intelligence already assists in automatic anatomy design, and 3D printing enables manufacturing materials that previously could only be cast or milled.
Dental 3D printing has evolved from a technological curiosity to a daily production tool in many laboratories. The most commonly used technologies are:
3D printing is especially disruptive in clear aligner manufacturing, where sequential models are printed for thermoforming the splints. A laboratory producing aligners can print hundreds of models daily with a single large-format printer.
Managing multiple materials, suppliers, batches, and expiry dates is a considerable logistical challenge. Software for dental laboratories allows you to associate each case with the material used, record batches for traceability, control stock, and generate consumption reports by material type.
When a clinic places an order through the platform, the product form already specifies the available material options. The technician knows exactly which material to use, the system records the batch employed, and if an issue ever arises with a specific batch, you can trace all affected cases in seconds.
The advantages of using dental management software multiply when you work with multiple materials and need to maintain complete traceability of every restoration manufactured.
DoYourLab lets you configure your product catalog with the exact materials you offer, manage orders digitally, and maintain complete traceability for every case. Try it free for one month. See plans
Choosing the right material for a dental prosthesis depends on multiple factors that the dentist and prosthetist must evaluate together:
The dental laboratory plays a fundamental consultative role in this decision. A skilled prosthetist can recommend the optimal material based on experience with similar cases, prosthetic space limitations, and patient expectations.
If you want to see how DoYourLab can help you manage all these materials and workflows, try the demo or create your platform directly.