Fabrication of a screw-retained implant-supported maxillary restoration. A completely digital workflow

Rinke, S., and Ziebolz, H., 2022

Implants - International Magazine of Oral Implantology, Issue 2, 2022

This case report shows a fully digital protocol using multi unit abutments, NEXUS IOS® scan gauges and a high-definition scanning strategy to capture full arch data and produce temporary and definitive restorations in three visits.‌

The authors explain that asymmetric scan gauges with enlarged reference surfaces and a unidirectional scan path reduce mismatches and stitching errors for edentulous jaws and angulated implants.

The digital workflow in this report used NEXUS IOS® scan gauges and produced a good fit and high patient satisfaction, while the authors note external validation of manufacturer data is still desirable.

NEXUS IOS® scan gauges, combined with an indication specific scan strategy, are shown here to improve full arch scan precision, support a shortened (three appointment) digital workflow and produce a well-fitting final restoration.

Full-arch restoration with the NEXUS IOS® system: a retrospective clinical evaluation of 37 restorations after a one year of follow-up

Klein, M., Tuminelli, F.J., Sallustio, A., Giglio, G.D., Lerner, H.,
Berg, R.W. and Waltuch, A., 2023

Journal of Dentistry, 139, p.104741.

This multicenter clinical report followed 29 patients who received 37 full-arch implant-supported restorations made with the NEXUS IOS® digital workflow and found all 37 prostheses clinically acceptable at delivery and an implant survival rate of 100% at one year.

The paper describes the NEXUS IOS® workflow (metal scan gauges with unique library files, proprietary AI validation and Nexus Portal) and explains how those components help reduce errors from manufacturing tolerances and stitching during full‑arch scanning.

The outcomes from using the NEXUS IOS® system in this trial are "excellent clinical results" including optimal passive-fit, marginal integrity, high short term survival, and low complication rates at one year.

Laboratory Evaluation of Novel Implant Metal-Acrylic Prosthesis Design: Influence of Monolithic Acrylic Veneer

El-Haddad, H., Judge, R.B., Abduo, J. and Palamara, J., 2020

International Journal of Oral & Maxillofacial Implants, 35(1)

This laboratory study compares a digitally designed metal‑acrylic hybrid prosthesis against a conventional design with acrylic denture teeth over a metal framework and retention pins. It found the digital prostheses sustained significantly higher load‑to‑failure (mean: 1,570 N vs 1,015 N) and far more cycles until failure under fatigue testing.

The authors report that the digital design produced more favorable, less catastrophic veneer failure patterns and that the digital manufacturing approach (CAD/CAM milled veneer and framework) avoids many manual processing flaws seen in conventional techniques.

The study supports that a fully digital workflow including CAD/CAM prosthesis design and manufacturing, such as those used by NEXUS IOS® and Osteon Medical, can produce prostheses with higher strength and more repairability.

A Case Report: Replication of an Implant Superstructure Using an Intraoral Scanner and a New Scan Gauge

Arai, M., Orita, T., Sato, Y., Katayama, S., Sakurai, Y., Matsuo, K.,
Ishiwata, H. and Sawase, T. 2022

Journal of the Japanese Society of Oral Implantology, 35(1), pp. 24–28.

This clinical case used an intraoral scanner plus novel scan gauges (NEXUS iOS® scan gauges) to reproduce a failing full‑arch prosthesis and deliver a zirconia full‑bridge in two visits, showcasing a fast, accurate workflow.

The authors report that scanning the mouth and the provisional restoration produced integrated STL data in about three days and allowed production of the new prosthesis in roughly 15 days, reducing visits and patient discomfort compared with conventional silicone impression techniques.

Using the NEXUS IOS® scan gauges enabled reproduction of the prosthesis with very high accuracy while reducing appointments and patient burden, demonstrating Nexus‑style scan gauges can make re‑fabrication faster and more precise.

Full arch reconstruction with Nexus iOS

Lerner, H., 2023

The Magazine of Digital Dentistry Society International, May Issue, 2023

This clinical case shows a full-arch immediate-placement rehabilitation where NEXUS IOS® scan gauges were used to capture implant positions and produce a precisely fitting provisional, on the same day of surgery.

The report documents coordinate comparisons, showing the NEXUS IOS® scan gauges produced very small deviations versus other acquisition systems and describes how data was uploaded to the NEXUS IOS® cloud (Portal), merged with library files and the wax‑up and an STL provisional was printed and delivered that day with excellent fit.

The NEXUS IOS® scan gauges enabled a "precise, pure digital workflow" that delivered a stable, aesthetic and passive‑fit provisional on the day of surgery and allowed highly reproducible final restorations.

A Paradigm Shift Using Scan Bodies to Record the Position of a Complete Arch of Implants in a Digital Workflow

Giglio, G.D., Giglio, A.B. and Tarnow, D.P., 2024

International Journal of Periodontics & Restorative Dentistry, 44(1), pp.115-126

This article explains how using horizontal scan gauges instead of traditional vertical scan bodies make full-arch implant scans more accurate and easier for the IO scanner to capture.

The authors describe how NEXUS IOS® scan gauges provide larger, multi‑planar reference surfaces and coded libraries for each gauge, which reduces stitching errors and manufacturing tolerance problems when creating a virtual master design.

In a clinical case, the authors uploaded scans to the Nexus Portal and used the scan gauge scans plus AI processing (Nexus Analyzer) to produce a calibrated virtual design and well‑fitting titanium hybrid prosthetic.

The article presents the style of NEXUS IOS® scan gauges as engineered to reduce stitching and manufacturing-tolerance errors and to permit more accurate full-arch implant scanning by enabling better z-axis data capture and individualized scan gauge library referencing.

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