Denture-to-fixed conversion is more than a simple pickup — it’s a coordinated process that transforms a removable denture into a fixed implant-supported provisional on the day of surgery. For implant-driven dentists and full arch focused doctors, this conversion is often the most stressful point of the treatment. Without a supportive lab partner, you’re left to manage chairside adjustments, occlusal surprises and patient expectations within a tight window.
What Is Denture-to-Fixed Conversion?
Denture conversion is the process of transforming a removable denture into a fixed provisional prosthesis on the same day implants are placed. The procedure is usually performed immediately or within 24–48 hours after implant placement so that the patient leaves surgery with a full arch restoration in place. Because the provisional is fixed to multi‟unit abutments, its fit, occlusion and esthetics set the tone for the entire case.
Traditional vs Digital (Smart) Conversion Workflows
In a traditional chairside conversion, the pre‑made denture is relined and picked up with temporary cylinders using an open‑mouth technique. Doctors or assistants may spend hours adjusting for occlusion, verifying passive fit and contouring the provisional. This familiar workflow doesn’t require pre‑surgical digital planning, but it depends on clinical labor and may invite errors due to open‑mouth pickup.
In a smart or digital workflow, the provisional is designed and duplicated digitally before surgery. Photogrammetry and CBCT data are used to plan implant positions and design the provisional, which is then duplicated ahead of time. On surgery day the provisional is seated using a closed‑mouth pickup, locking in occlusion and reducing chairside time to about 30 minutes. Months later, the same design file is used to mill the final zirconia prosthesis.
Pros of Smart Conversion
- Reduces chairside time to around 30 minutes.
- Closed‑mouth pickup improves occlusal accuracy.
- Stronger, digitally duplicated provisionals with refined esthetics.
- Seamless transition to final prosthesis using the same design file.
Pros of Traditional Conversion
- Familiar workflow for many teams and adaptable on the day of surgery.
- No requirement for pre‑surgical digital planning.
- Flexible when unexpected implant changes occur.
Cons of Traditional Conversion
- Chairside processing can take 2+ hours.
- Open‑mouth pickup may lead to occlusal errors and misfit.
- More chairside stress and adjustments; risk of microfractures requiring repair.
Why Passive Fit Matters in Full‑Arch Restorations
Passive fit means the provisional or final prosthesis seats on the implants without tension. Even minor misalignment can lead to screw loosening, fractures, biological complications and long‑term instability. Digital workflows help achieve passive fit by verifying scan integrity, using implant verification jigs and including a provisional try‑in. Glidewell’s OPTISPLINT® digital workflow, for example, offers a provisional try‑in implant prosthesis to verify design before milling the final monolithic zirconia restoration.
Monolithic Zirconia: Strength and Esthetics for Full‑Arch Cases
Monolithic zirconia full‑arch prostheses, such as the BruxZir® Esthetic Full‑Arch Implant Prosthesis, are milled from a single block of high‑strength zirconia (around 870 MPa flexural strength). They avoid the chips, stains and fractures that can compromise acrylic hybrids and dental porcelain. Detailed gingival anatomy and incisal translucency provide premium esthetics, while provisional try‑ins and digital copy‑milling ensure a passive fit before the final restoration is fabricated.
Benefits of Monolithic Zirconia Full‑Arch Prostheses
- High flexural strength (approximately 870 MPa) for long‑term durability.
- Premium esthetics with lifelike translucency and gingival detail.
- Reduced risk of chips, stains and fractures compared with acrylic hybrids.
- Digital workflows with provisional try‑ins ensure passive fit and predictable outcomes.
- Copy‑mill services allow duplication from approved setups for consistent final restorations.
How a Specialized Lab Streamlines Full‑Arch Conversions
A full‑arch conversion workflow relies on collaboration with a lab that understands the nuances of All‑on‑X and denture conversion. A specialized lab will:
- Review CBCT and intraoral scans to plan implant positions and provisional design.
- Provide digital wax‑ups, implant verification jigs and provisional duplicates.
- Use provisional try‑ins to verify fit and occlusion before milling final zirconia.
- Offer guidance on material selection and occlusal management for parafunctional patients.
- Coordinate timelines so provisional and final prostheses arrive when needed.
As you refine your full‑arch workflow, remember that your lab partner plays a pivotal role.
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For more insights on reducing conversion stress and improving All‑on‑X outcomes,
read our article on All‑on‑X Dental Lab Support: How to Reduce Conversion Stress and Improve Full‑Arch Outcomes.
