/ Design / Full-Arch & All-on-X
Advanced Full-Arch Production — Integra Dental Design
Full-arch All-on-X production,
including angled screw channels
most labs can’t mill.
Integra Dental produces full-arch zirconia restorations with multi-unit angled screw channels up to 30 degrees. Cases that most labs decline or outsource — including complex All-on-X and All-on-4 geometries with divergent implant axes — are within standard production scope here. Every arch is designed, milled, and sintered in-house on a validated program.
Up to 30° Angled Channels
5-Axis Wet Milling
Validated Sintering Protocol
Day-of-Surgery Support Available
Why Most Labs Decline These Cases
Angled screw channels are a CAM problem, not just a machine problem.
When implants are placed at angles to compensate for bone anatomy in All-on-X and All-on-4 cases, the resulting screw channels in the prosthesis must follow the implant axis — not the vertical axis of the restoration. Channels angled beyond approximately 17 degrees create complex undercut geometries that most CAM software cannot resolve cleanly, and that most mills cannot navigate without tool collision or surface artifact.
The result is that many dental labs either decline these cases outright, refer them to specialized milling centers, or produce restorations with compromised channel integrity that lead to seating problems, screw access issues, or premature fracture.
Solving this requires a combination of full 5-axis simultaneous milling capability, operator-level CAM expertise, correct toolpath strategy and tooling selection for the specific channel geometry, and a sintering program validated for the resulting wall thickness at the channel intersections. Integra Dental has all four.
Full 5-axis simultaneous milling on Arum 5X-200.
The Arum 5X-200 operates with full simultaneous 5-axis movement — meaning all five axes can move concurrently during cutting rather than sequentially. This is what allows the tool to follow angled channel geometries without repositioning the workpiece or approximating the path with indexed steps that leave facets and surface inconsistency.
ApexMill and MillBox CAM with operator-level toolpath strategy.
CAM software generates the toolpath, but the strategy — approach angle, tool engagement, stepover, finish pass direction — requires the operator to understand what the geometry demands. A certified CAD/CAM specialist with six-plus years of full-arch production experience sets every toolpath on complex cases. Angled screw channels up to 30 degrees are within standard production scope.
Validated sintering profiles for complex geometries.
Angled channel geometries create variable wall thicknesses and stress concentration points that require a sintering program matched to the specific material and geometry — not a generic profile. Our sintering programs for B&D Multi-Y full arches were developed through documented R&D on our Dekema Austromat furnace, with particular attention to cooldown rate and bead support positioning for cases with channel intersections.
Full-Arch Case Types
Every stage of the implant arch workflow.
From the day-of-surgery provisional to the definitive zirconia prosthesis, Integra Dental produces every arch type in the All-on-X workflow. Cases are designed to your surgical protocol and implant data — not adapted from a template.
Stage 1 — Day of Surgery
Immediate Provisional Design
Post-placement scan received, full-arch provisional designed and delivered as a printable STL within minutes. Practice prints chairside on an Asiga MAX UV. Patient leaves with a seated provisional the same day. Available as a standing arrangement for surgeons who perform regular implant cases.
See Day-of-Surgery Workflow →
Stage 2 — Provisional Prosthesis
PMMA Full-Arch Hybrid
Multilayer PMMA hybrid provisional milled in-house. Designed to the final prosthetic plan with correct occlusion, emergence, and screw channel geometry — including angled channels. Immediate load compatible. Available with or without angled screw channel requirements.
From $999 / arch
Stage 3 — Definitive Prosthesis
Zirconia Hybrid & Ti-Bar
Full-arch zirconia hybrid prosthesis with angled screw channels to match the surgical protocol. Designed in-house, milled on 5-axis Arum 5X-200, sintered on a validated Dekema program. Also available with a milled titanium bar framework for maximum structural rigidity in demanding clinical situations.
Zirconia from $1,999 · Ti-bar from $2,499
Also Available for Dental Labs
Labs can outsource their hardest full-arch cases to us.
If your lab has full-arch cases with complex angled screw channel geometries that fall outside your milling capability, Integra Dental accepts these cases as a lab-to-lab milling partner. Send your design file, we mill and sinter it, and it returns to you under your brand. Your client relationship stays intact. We do not contact your doctor or surgeon.
Lab-to-Lab Full-Arch Rates
Standard arch — mill & sinter
$600
Angled channel cases
Contact us
Design + manufacture
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Implant System Compatibility
Compatible with all major implant platforms used in full-arch cases.
All-on-4 and All-on-X cases involve implant systems from Nobel Biocare, Straumann, Zimmer Biomet, Neodent, Osstem, BioHorizons, MegaGen, and others. Confirm your specific platform and connection type before submitting a first case.
Nobel Biocare — Active, Replace, All-on-4
Straumann — BL, TL, Pro Arch
Zimmer Biomet — TSV, Trabecular Metal
Neodent — GM, Helix, Grand Morse
Osstem — TS III, US II
BioHorizons — Tapered Internal
MegaGen — AnyRidge, AnyOne
Dentsply Sirona — Astra, XiVE
+ most major platforms
Integra Dental
Digital dental production — restorations, milling, and equipment. Bellevue, WA.
Precision, made personal.
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Contact
(425) 736-9381
hello@integra.dental
Bellevue, WA 98007