From Analogue to Digital: Where Should Your Laboratory Start?
- Stuart Anderton
- Jul 27
- 13 min read
Going digital does not mean buying a room full of equipment at once. The safest and most profitable approach is to digitise one part of your existing workflow, make it pay for itself and then add the next part.
The right starting point is different for every laboratory. A crown and bridge laboratory, a removable laboratory and an AOX laboratory do not make the same products, use the same materials or lose money in the same places.
Before choosing any equipment, begin with a much simpler question:
What do you already make manually, in sufficient volume, that could be manufactured faster or more consistently with a digital workflow?
Your answer should determine what you buy and in what order.
Start with the restoration, not the machine
It is easy to become interested in a particular printer or mill and then look for work to put through it. This reverses the decision-making process.
Instead, list the restorations your laboratory currently produces:
Zirconia crowns and bridges
Glass ceramic restorations
PMMA provisionals
Implant restorations
AOX prostheses
Full dentures
Partial dentures
Splints
Models
Surgical guides
Custom trays
Orthodontic appliances
For each product, record:
How many you produce each week
How much you currently spend outsourcing it
How many technician hours it requires
Where delays and remakes occur
How quickly customers expect delivery
Whether demand is stable or occasional
Whether your team already understands the restoration manually
Digital equipment is most valuable when it improves a product you already understand. A design service, printer or mill will not replace knowledge of anatomy, occlusion, materials, fit or finishing. It changes how that knowledge is applied.
The questions every laboratory should ask
Before buying anything, ask yourself the following questions.
What do we make most often?
High-volume, repetitive work usually gives the fastest return. Saving a small amount on hundreds of units can be more valuable than saving a large amount on an appliance made only occasionally.
The best first digital product is often something the laboratory already manufactures every day.
What do we currently manufacture manually?
Look at every step required to produce the restoration and identify where technician time is being consumed.
This may include:
Pouring and trimming stone
Waxing restorations
Blocking out models
Duplicating models
Processing acrylic
Thermoforming
Investing and casting
Trimming
Adjusting
Polishing
Repeating work after distortion or processing errors
A digital workflow may not eliminate finishing, but it can remove many of the repetitive production steps that come before it.
What do we currently outsource?
Regular outsourcing costs can show which manufacturing process may be profitable to bring in-house.
Add together:
Manufacturing charges
Freight
Rush fees
Remakes
Delays
Administrative time
Minimum order charges
Lost production control
Do not look only at the supplier’s price per unit. Calculate the complete cost to your laboratory.
Design and manufacturing are separate decisions. A laboratory can continue to outsource digital design while bringing manufacturing in-house.
Where is our biggest bottleneck?
Your problem may be:
Waiting for designs
Pouring and trimming stone
Waxing restorations
Producing models
Waiting for outsourced manufacturing
Finishing poorly designed restorations
Repeating work because information was lost between steps
Relying on one technician for a manual process
Lacking production capacity during busy periods
Buy the equipment that removes the actual bottleneck. A faster mill will not help if completed cases are sitting for several days waiting to be approved or finished.
Which manually manufactured restoration would benefit most?
Look for a product that is currently:
Labour intensive
Repetitive
Difficult to scale
Regularly outsourced
Subject to long turnaround times
Dependent on one skilled technician
Produced in sufficient volume
Suitable for repeatable digital manufacturing
The first digital workflow should solve an existing production problem. It should not create a completely new product category that your laboratory then has to find customers for.
Do we want to design, manufacture or both?
These are separate decisions.
A laboratory can:
Receive a digital scan, outsource the design and manufacture the restoration in-house.
Design the restoration internally and manufacture it in-house.
Use a combination of internal and outsourced design, depending on the restoration.
You do not have to bring every part of the workflow in-house from the beginning.
For many manually operated laboratories, the first option is the most practical and profitable place to start. The laboratory outsources the unfamiliar CAD work but keeps manufacturing, material selection, finishing and quality control in-house.
Who will operate the system?
Digital equipment needs a responsible operator. Someone must learn the workflow, prepare files, maintain the equipment, manage materials, monitor quality and troubleshoot routine problems.
Ask:
Who will be responsible for the machine?
Do they have enough time to operate it properly?
Who will cover the role during leave?
Who will complete daily and weekly maintenance?
Who will inspect the manufactured work?
Can more than one person run the workflow?
If nobody has the time or interest to take ownership, the equipment may sit idle regardless of its capability.
What happens if the machine stops?
Before bringing a production step in-house, decide how work will continue during maintenance or repair.
This could mean:
Having access to another compatible machine
Maintaining enough capacity across several systems
Keeping common replacement parts and consumables available
Scheduling preventative maintenance
Allowing spare capacity for urgent or repeated work
Having a backup production arrangement for extended downtime
Choosing to operate without redundancy is a business decision made by the laboratory. If the laboratory relies entirely on one machine, any breakdown, scheduled maintenance or delay obtaining parts may interrupt production.
The manufacturer and supplier remain responsible for meeting their service and warranty obligations. They are not responsible for the laboratory’s decision to operate without backup capacity or for the resulting loss of production.
A machine operating at its maximum capacity every day also has no room for urgent work, maintenance or recovery following a failed job. Redundancy and spare capacity should therefore be considered part of production planning, not an optional response after downtime occurs.
The lowest-risk way to begin
Most laboratories now receive a significant proportion of their work as digital scans directly from clinics. This means a laboratory scanner is no longer the automatic first purchase it once was.
For many manually operated laboratories, a practical starting workflow is:
Receive the digital scan from the clinic.
Check the scan and prescription.
Send the case to a digital design service.
Review and approve the completed design.
Import the manufacturing-ready file into the printer or mill software.
Manufacture the restoration in-house.
Complete post-processing, finishing and quality control.
Deliver the finished restoration to the clinic.
This approach allows the laboratory to begin digital manufacturing without immediately purchasing complex design software or employing an experienced CAD designer.
It also keeps the laboratory involved in the parts of the workflow it already understands, including materials, manufacturing, fit, finishing, characterisation and final quality.
What should you buy first?
Stage 1: A capable computer and organised digital workflow
Every digital workflow depends on the computer running it. Manufacturing software uses 3D rendering, large datasets and intensive calculations to prepare files for printing or milling.
The computer is not an accessory. It is part of the production system.
Begin with a computer that meets the requirements of all the software and equipment you intend to use. An underpowered computer can cause:
Freezing
Crashes
Slow calculations
Failed processing
Interrupted production
Difficulty handling large cases
You should also establish:
Consistent file naming
Secure case storage
Regular backups
Digital prescriptions
Clear design approval procedures
A method for tracking revisions
A method for storing final manufacturing files
Clear responsibility for each production stage
Without this foundation, adding equipment simply creates a faster way to produce disorganised work.
Stage 2: Access to a design service
The incoming scan provides the patient geometry, but it does not create a restoration. A design must be completed before the restoration can be printed or milled.
For many laboratories, outsourcing design is the easiest and most profitable first step.
A design service allows the laboratory to:
Accept digital cases immediately
Avoid purchasing every CAD software module
Avoid annual software costs during the early stages
Access experienced designers
Add new restoration types gradually
Pay for design according to actual case volume
Focus staff on manufacturing and finishing
Learn what good digital designs should look like
The completed design can be reviewed by the laboratory and imported into the appropriate CAM or build-preparation software.
Before choosing a design service, ask:
Which restorations can it design?
How quickly are designs returned?
Can the design be revised?
Can the laboratory review and approve it before manufacturing?
Are open, manufacturing-ready files supplied?
Are the required implant libraries available?
Can the designer follow laboratory-specific preferences?
How are complex instructions communicated?
What happens if the original scan is incomplete?
Who is responsible for identifying inadequate scan data?
The cheapest design is not necessarily the most profitable. A poorly designed restoration can waste material, occupy the machine twice and create additional finishing work.
Stage 3: The manufacturing equipment that solves your biggest problem
Once the laboratory can receive scans and obtain completed design files, it can manufacture the work locally.
The first machine should be selected according to:
Existing case volume
Current outsourcing costs
Manual labour requirements
Materials used
Required turnaround
Available staff
Available space
Post-processing requirements
Service and technical support
Expected operating cost
The best first machine is generally the one that replaces the laboratory’s largest stable outsourcing expense or its most labour-intensive manual process.
Choosing your first manufacturing system
3D printing
A dental 3D printer usually has a lower entry cost than a milling system and can manufacture a broad range of products, depending on the printer and validated materials.
Common applications include:
Dental models
Splints
Surgical guides
Custom trays
Denture bases and teeth
Denture try-ins
Gingival masks
Castable patterns
Temporary restorations
Selected permanent restorations
Printing can be a strong first manufacturing step for laboratories producing models, splints, guides or removable appliances.
For example, a manually manufactured splint may require model preparation, blocking out, duplication, thermoforming or acrylic processing, trimming, adjustment and polishing. A digital workflow can replace several of these steps with a repeatable design and printing process.
However, the printer is only one part of the system. You must also allow for:
Build-preparation software
Validated resins
Washing equipment
Curing equipment
Personal protective equipment
Resin storage
Waste handling
Replacement tanks or films
Build platforms
Cleaning materials
Labour for washing, curing and finishing
Material-specific validation requirements
A cheap printer does not automatically create a cheap restoration. Calculate the complete process from receiving the file to completing the finished appliance.
Dry milling
For laboratories with consistent zirconia, PMMA or wax volume, a dry mill can be one of the most profitable manufacturing investments.
The strongest business case is often zirconia because it combines regular demand with the ability to nest multiple restorations in one disc. The saving per unit can become significant when the machine is kept productively occupied.
A dry-milling workflow will also require:
CAM software
Dust extraction
Compressed air, unless the mill does not require it
Milling tools
Material discs
A zirconia sintering furnace
Colouring, staining and glazing materials
Finishing equipment
Calibration and maintenance
Backup manufacturing arrangements
Do not calculate profitability using only the cost of a zirconia disc. Include:
Milling tools
Unused material within the disc
Technician labour
Furnace time
Electricity
Maintenance
Failed units
Remakes
Finance costs
Software licences
Equipment depreciation
A dry mill is likely to be a strong first investment when a laboratory already manufactures or outsources a consistent number of zirconia restorations every week.
Wet milling
Wet milling is generally used for materials such as glass ceramic, lithium disilicate, hybrid ceramic and selected titanium applications.
It can be attractive when the laboratory has regular demand for same-day or short-turnaround restorations. It may also complement a dry mill by covering materials that should not be processed dry.
A wet-milling workflow may require:
Material blocks
Milling tools
Coolant or water-management consumables
A suitable furnace for crystallising and glazing
Cleaning and maintenance
Material-specific CAM strategies
Finishing and polishing equipment
A wet mill should be selected when the volume of suitable restorations and the value of controlling turnaround justify the investment.
Metal milling
Milling titanium or other metals involves greater equipment cost, more demanding manufacturing conditions and more expensive tools.
It generally makes sense only where the laboratory has sufficient, predictable volume and the technical ability to maintain a controlled process.
For many laboratories, specialist metal components may remain the exception while more common restorations are manufactured locally.
What is usually the most profitable first step?
There is no single answer, but some patterns are common.
For many manually operated laboratories, the most profitable starting point is to outsource the digital design and manufacture the restoration in-house.
This avoids the immediate cost and learning curve of CAD software while allowing the laboratory to control material selection, production, finishing, quality and turnaround.
Crown and bridge laboratories
A laboratory producing a consistent volume of zirconia crowns and bridges may achieve its fastest return from a dry mill and sintering furnace. Completed designs can be supplied by a design centre and imported directly into the CAM software.
This brings a regular manufacturing expense in-house without requiring the laboratory to employ an experienced CAD designer from the beginning.
If glass ceramic restorations form a substantial part of the workload, a wet mill and suitable furnace may be the better first investment.
Laboratories producing models, splints and guides
A 3D printer can be a strong first investment where the laboratory produces large numbers of models, splints, surgical guides or custom trays.
These products can be printed in batches, reducing repetitive manual work and increasing the number of appliances that can be produced by the same team.
The complete workflow must be considered. Washing, curing, validated materials, consumables and finishing are just as important as the printer itself.
Removable laboratories
For a removable laboratory, the best starting point depends on which manual process consumes the most time.
A printer may be used for:
Denture try-ins
Denture bases
Denture teeth
Custom trays
Models
Other removable components
The laboratory can initially outsource the denture design and manufacture the approved files locally. This allows technicians to keep control of processing, assembly, characterisation and finishing while gradually becoming familiar with digital production.
AOX and implant laboratories
AOX and implant laboratories should begin with the process that matches their main material and restoration type.
This may involve:
Printing temporary or permanent prostheses
Milling PMMA
Milling zirconia
Producing models
Producing verification components
Manufacturing try-ins
Because these are high-value restorations, the decision should not be based only on the cost per unit. Production control, material options, turnaround, backup capacity and the cost of a failed case must also be considered.
Laboratories with low or mixed digital volume
A laboratory does not need a large digital workload before it begins manufacturing in-house. Where individual product volumes are low, the best first investment may be a versatile machine that can produce several of the restorations the laboratory already makes.
A 3D printer may be suitable for laboratories producing a mixture of models, splints, guides, trays, denture components and temporary restorations. A suitable mill may be a better choice where the laboratory’s work is concentrated around zirconia, PMMA, wax or glass ceramic.
The laboratory can outsource the design, receive a manufacturing-ready file and complete the CAM preparation, manufacturing, post-processing and finishing in-house. This keeps the initial workflow simple while allowing several product categories to contribute towards the cost of the equipment.
The most profitable first machine is generally the one that replaces the greatest amount of manual labour across the laboratory’s real workload. It does not need to manufacture everything, but it should be useful often enough to earn its place in the laboratory.
Compare the digital process with the manual process
The value of digital manufacturing is not limited to the difference in material cost.
For a manually manufactured restoration, consider:
Hands-on technician time
Waiting time between stages
Number of separate materials
Number of opportunities for distortion
Remake risk
Finishing time
Training required
Dependence on individual manual skill
Maximum daily capacity
Then compare the proposed digital workflow:
Design fee
File preparation time
Machine time
Material cost
Post-processing time
Finishing time
Consumables
Maintenance
Remake risk
Daily capacity
Machine time is not the same as labour time. A printer or mill may operate for an hour while the technician completes other productive work.
The most useful saving is often not a cheaper material. It is the technician time released for work that requires judgement, experience and artistry.
Calculate the return using real production numbers
A simple calculation is:
Monthly benefit = outsourcing costs avoided + labour savings + additional gross profit − new monthly operating costs
New operating costs include:
Finance repayments
Software licences
Design fees
Materials
Tools and consumables
Staff time
Maintenance
Service contracts
Remakes and failures
Electricity
Waste disposal
Training
Equipment depreciation
Then calculate: Payback period = total initial investment ÷ monthly benefit
Be conservative. Do not base the calculation on the maximum number of units a machine can theoretically produce.
Use your actual case volume and allow for:
Quiet periods
Maintenance
Staff leave
Failed jobs
Remakes
Training time
Urgent work
Material changes
Machine cleaning
Post-processing
A machine that could manufacture 500 units each month is not profitable if your laboratory only has demand for 50.
However, a versatile system does not need high volume in one product if several existing product categories can keep it in regular use.
A sensible purchasing order
For many laboratories, the following order provides a manageable path:
Map the current manual workflow and identify the bottleneck.
Choose the existing restoration with the strongest volume and clearest return.
Install a suitable computer and digital case-management process.
Begin receiving digital scans from clinics.
Use a design service to obtain manufacturing-ready files.
Purchase the machine that replaces the greatest manual workload or regular manufacturing expense.
Add the required validated post-processing equipment.
Train staff in CAM preparation, manufacturing, maintenance and quality control.
Measure actual production costs and savings.
Bring design in-house when the volume and staffing justify it.
Add the next manufacturing process when demand supports it.
This order allows the laboratory to control production and finishing from the beginning without taking on every part of the digital workflow at once.
Do not buy around one unusual case
A machine should be selected around the work that keeps the laboratory busy every week, not a complicated restoration that appears twice a year.
A strong digital laboratory knows:
Which work to automate
Which work to batch
Which materials it uses regularly
Which processes consume the most labour
Which restorations justify dedicated equipment
When another machine is commercially justified
Owning more equipment does not automatically make a laboratory more digital or more profitable.
Open workflow matters
An open workflow allows the laboratory to move files between compatible intraoral scanners, design services, design software, printers and mills.
Before purchasing, ask:
Can I import standard file formats?
Can I receive files from different design services?
Can the system accept files from the scanners my customers use?
Can I change materials or suppliers?
Can another compatible machine manufacture the file during downtime?
Who owns and controls the case data?
Can I access completed files in the future?
An integrated workflow can be convenient, but convenience should not leave the laboratory unable to operate without one supplier or platform.
Training is part of the investment
Digital manufacturing is not simply pressing a button.
Staff must understand:
Digital case assessment
Design approval
Material selection
CAM preparation
Nesting and orientation
Printer or mill setup
Post-processing
Finishing
Quality control
Routine maintenance
Troubleshooting
When a scan or design should be rejected
The best equipment will still produce poor results when the scan, design, manufacturing strategy or finishing process is wrong.
Choose a supplier like Osseo Group that can support the complete workflow, not just deliver the machine.
Build a digital laboratory one profitable step at a time
The purpose of going digital is not to own more equipment. It is to produce good restorations more consistently, reduce unnecessary labour, improve turnaround and create additional capacity.
Begin with what you already make well manually.
Identify the restoration that consumes the most labour or attracts the largest regular manufacturing cost. Outsource the unfamiliar design stage, manufacture the restoration locally and keep control of the material, finishing and final result.
Once that workflow is productive and profitable, decide which process should come next.
Receive. Design. Manufacture. Finish.
Your laboratory does not need to bring every stage in-house on the first day. Start with the part that delivers the clearest financial and production benefit, then build from there.
Where to go from here?
If you are unsure where to start, Osseo Group can review your current product mix, outsourcing costs, case volume and staff capability. We can then help you build a staged digital workflow based on what will be useful and profitable in your laboratory, not simply on how many machines can fit through the door.
Book a demo or Chat with one of our product specialists to discuss the right starting point for your laboratory.
