What Your Scanner Company Won't Tell You About Scanning

Why 95% of Intraoral Scans Fall Short: The Problem Nobody Talks About

Here's something most labs won't tell you: less than 5% of the scans they receive are truly ideal. Not "unusable." Not "rejected." Just... not ideal. The other 95% require workarounds, assumptions, or compromises that affect the final result.

The Lab Owner's Perspective

At DSD, we've analyzed over 10,000 scans from dentists around the world. We see everything — the good, the mediocre, and the "how did they think this would work?"

And here's what we've learned: the difference between a good scan and a great scan isn't the scanner. It's technique. It's knowing what to check before you hit send. It's understanding what happens on our end when your file arrives.

The Real Cost

Poor scanning is expensive. Not just in remakes — though those add up — but in chair time spent adjusting restorations that "almost" fit, patient trust eroded by multiple appointments, lab relationships strained by finger-pointing, and your own confidence undermined by unpredictable results.

The frustrating part? Most of these issues are preventable.

Bite Registration Errors: The #1 Hidden Cause of Remakes

The #1 Issue We See

If we could only fix one scanning problem across all our cases, it would be bite registration.

Bite errors are responsible for more remakes, adjustments, and patient complaints than any other single issue. And they're almost always invisible on your screen.

Two Problems, Hidden by Software

Problem 1: Occlusal Collision

The upper mesh penetrates into the lower mesh in places where the teeth don't actually touch. Your scanner shows a closed bite. The reality is different.

Result: We design a restoration around false contact points, creating an under-contoured crown that's too short in occlusion.

Problem 2: Occlusal Gap

Space appears between meshes where the teeth actually make contact. Your scanner shows separation. The patient's mouth shows contact.

Result: We design to fill a gap that doesn't exist, creating an over-contoured crown that's too tall.

Why Your Scanner Hides This

Modern scanning software is designed to make everything look good on screen. It automatically fills gaps, smooths intersections, and presents a "clean" model.

That's great for visualization. It's terrible for accuracy.

The software is guessing. And guesses become problems when the restoration doesn't fit.

The Solution: Visual Verification

Before sending any scan, inspect the bite in sagittal (side) view. Most scanners have a slice or cross-section tool. Use it.

Look for places where meshes penetrate each other or separate where they shouldn't.

Tools like BiteFinder can automate this check, but even a manual visual inspection catches most problems.

Occlusal artificial collision vs. occlusal artificial gap

The Complete Patient Avatar: 5 Scan Components Most Dentists Miss

A crown scan isn't just about the prep. For truly predictable results — especially in esthetic cases — we need a complete patient avatar.

The 5 Components

1. Intraoral static
2. Intraoral motion
3. Facial static
4. Facial motion
5. Inner tissues

The File Matching Challenge

When different scans are captured at different times (prep, bite, facial scan), they need to be matched together. This is where problems compound. If your scan extension is insufficient, we can't reliably match files. If landmarks don't align, we're making assumptions.

New Solutions

Tools like Qlone Dental and ModJaw are making it easier to capture complete patient avatars with accurate file matching. The technology is advancing rapidly. But regardless of tools, understanding what a complete avatar requires is the first step.

Jaw tracking with tools such as ModJaw.

Full Arch Implant Scanning: Why No Scanner Can Guarantee Passive Fit

Full arch implant cases represent the most challenging intraoral scanning scenario because no current scanner — regardless of brand or price — can reliably capture full arch implant positions with the accuracy required for passive fit, due to cumulative stitching distortion across the arch.

The Physics Problem

Intraoral scanners work by stitching together thousands of small images. Each individual scan is accurate. But as you move across a full arch, micro-distortions accumulate. By the time you've scanned from second molar to second molar, those tiny errors have compounded into measurable deviation. For single crowns or small bridges, this doesn't matter. The error is within tolerance. For splinted implants across a full arch, it's the difference between a restoration that seats passively and one that rocks, gaps, or causes screw loosening over time.

The Solution — Photogrammetry Verification

Photogrammetry uses fixed reference points and triangulation to capture implant positions with laboratory-level accuracy. It doesn't accumulate stitching errors because it's not stitching — it's measuring absolute positions.

You don't need expensive dedicated equipment anymore. Smartphone-based photogrammetry solutions like PIC Dental turn your iPhone into a verification tool. The technology has become remarkably accessible.

Our Recommendation

For any case with 4 or more implants, verify with photogrammetry. Use your intraoral scanner for what it does brilliantly: capturing soft tissue, emergence profile, opposing arch, and bite. Let photogrammetry handle the implant positions.

Full arch implant scanning: where cumulative stitching error becomes clinically significant

15 Common Intraoral Scanning Mistakes Labs See Every Day

Based on reviewing thousands of cases, here are the 15 most common issues we see—organized by category:

Which Ones Are You Committing?

Most dentists unknowingly make 3-5 of these errors regularly. Some are making more.

The first step to better outcomes is knowing where you stand.

Why Gingival Information Matters

For posterior crowns, soft tissue information is nice to have.

For anterior esthetics, it's essential.

The difference between a crown that "fits" and one that looks naturally emerged from the gingiva is soft tissue data.

Emergence Profile

Emergence profile—the way the crown transitions from the implant or root to the visible tooth—can make or break anterior aesthetics.

Without gingival architecture data, we're guessing at emergence. With it, we can design restorations that look like they grew there.

How to Capture It

For esthetic cases, scan the provisional in place. This gives us:

• The gingival contour the tissue has adapted to
• The emergence profile that works in the patient's mouth
• A template for the final restoration

Then scan the prepared tooth. The combination gives us everything we need.

The Provisional-to-Lab Workflow

1. Place provisional, allow tissue to adapt (if needed)
2. Scan provisional in place
3. Remove provisional, scan preparation
4. Send both scans with clear labeling

This extra step adds minutes to your workflow and transforms your esthetic results.

How to Master Your Intraoral Scanner — Regardless of Brand

Scanner mastery depends on technique rather than equipment — a skilled operator with a mid-range scanner will consistently outperform a mediocre operator with a premium device — yet less than 2% of dentists have truly mastered their intraoral scanner because advanced technique is rarely taught in manufacturer training or dental school.

It's Technique, Not the Tool

Here's a truth that scanner companies don't advertise:

A skilled operator with a mid-range scanner will consistently outperform a mediocre operator with a premium scanner.

The tool matters less than the technique. The scanner matters less than the scanning.

The 2% Who've Mastered It

Less than 2% of dentists have truly mastered their intraoral scanner.

Not because mastery is impossibly difficult, but because:

• Manufacturer training covers basics, not advanced technique
• The nuances aren't taught in dental school
• Expert knowledge is scattered across different practitioners
• Most dentists don't know what they don't know

Signs You're in the 2%

You know you've mastered your scanner when:

• Remakes are rare exceptions, not regular occurrences
• You can predict exactly what the lab will receive
• You understand your scanner's specific strengths and limitations
• You have systematic checks before every case
• Your lab comments on the quality of your scans

How to Evaluate Your Current Level

Be honest with yourself:

• Do you verify bite registration before every case?
• Can you identify mesh crashes before sending?
• Do you know your scanner's accuracy limitations for full arch?
• Have you asked your lab for honest feedback recently?

If you answered "no" to any of these, there's room to grow.

The IOS Festival

Everything on this page scratches the surface. The checklist helps you catch problems. But truly mastering your scanner requires going deeper.

That's why we created the IOS Festival—the only course in the world 100% dedicated to intraoral scanning mastery.

What Makes It Different

Scanning Mastery

Whatever intraoral scanner you use, you'll learn brand-agnostic tips and topics you can apply.

Real Practitioners, Real Techniques

No vendor presentations. No sales pitches. Just expert users sharing the advanced techniques that took them years to develop.

Brand-Agnostic Comparison

See how different scanners actually perform side-by-side. Understand real strengths and limitations. Make informed decisions.

Hands-On Learning

Practice advanced techniques with expert guidance. Walk away with skills, not just knowledge.

The Experience

Modena, Italy. Formula One experiences. World-class learning.

• Dinner at the Ferrari Museum
• Evening at the Pavarotti Museum
• Accommodations and meals included
• Community of practitioners committed to excellence

Course Details