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Crown & Bridge Blunders:
What’s Going Wrong and How to Fix It

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So, you've been working on crowns and bridges for a while now.

You’ve mastered the basics, you know the workflow, and your results are usually pretty solid. But every once in a while, something goes sideways.

Maybe it’s a crown that doesn't fit right or a bridge that just doesn’t have the smooth finish it should.

We’ve all been there.

Let’s face it – crown and bridge production isn’t always a smooth ride.

Even the best dental technicians run into problems now and then. But wouldn’t it be great if you could avoid those common pitfalls before they cost you time and materials (and maybe even your sanity)?

In this article, we’re going to dive into the most common mistakes that happen during crown and bridge production.

We’ll break them down and, more importantly, show you how to avoid them.

By the time you’re done reading, you’ll be armed with tips that’ll make your work more efficient, more accurate, and less frustrating.

1. Material Shrinkage – The Phantom Fit Issue

Let’s kick things off with one of the most annoying issues – material shrinkage.

You know the drill: everything looks great, and you’re sure the fit is perfect.

But after firing or pressing, the crown has mysteriously shrunk just enough that it doesn’t fit like it did on the model.

This is what we call the “phantom fit issue.” It’s a pain, but there are ways to handle it.

Why it happens: Shrinkage can occur because of how the material responds to heat.

Porcelain and zirconia are particularly notorious for this. Even a tiny miscalculation in your firing cycle can leave you with a restoration that’s just a little too tight.

How to avoid it:

• Know your materials: Every material has its quirks. For example, zirconia tends to shrink more than metal.

  Make sure you know the shrinkage factor of the material you’re using, and adjust your design accordingly. Check the manufacturer’s specs and follow them closely.

• Watch your firing cycles: It’s tempting to rush through the firing process, especially when you’re under pressure.

  But, trust me, this is where shortcuts come back to bite you. Make sure your temperature and time are dialled in.

• Use compensation strategies: You can also account for material shrinkage in your CAD/CAM software.

  Some systems allow you to build in compensation factors that adjust the design to offset the expected shrinkage during firing.

2. Poor Fit – The Margins of Error

Here’s another classic headache – poor fit.

There’s nothing worse than delivering a crown or bridge to the dentist only to hear that it’s not sitting right.

Margins aren’t sealed, or worse, it’s too tight.

Why it happens: Poor fit can come from many places – inaccurate impressions, sloppy scanning, or issues in the milling process.

Sometimes, the problem starts before you even touch the material.

How to avoid it:

• Perfect the impression: Whether you’re working with traditional impressions or digital scans, this is where precision starts.

  A bad impression means bad everything else. If you’re getting physical impressions, make sure they’re free of bubbles, distortions, or folds.

  With digital, double-check for accuracy.

• Control your model: Poor models mean poor results.

  Keep your stone models clean, and avoid trimming away crucial landmarks.

  And if you’re using digital models, make sure your scanning protocol is airtight.

• Master your design: When working with CAD software, avoid rushing through the design phase.

  Zoom in on those margins and fine-tune everything before sending it to the mill. In many cases, software allows you to visualize potential problem areas—and use those features to your advantage.

3. Contact Points – Either Too Tight or Too Loose

Finding the right contact points in crown and bridge work is like walking a tightrope.

Too tight, and you risk patient discomfort or damage to the adjacent teeth.

Too loose, and the restoration might fail or cause food traps, leading to decay and other issues. Neither outcome is good.

Why it happens: Inconsistent contact points can occur during the design phase, especially if you don’t take the time to carefully assess how the crown will fit within the context of surrounding teeth.

How to avoid it:

• Measure twice, mill once: Before you hit “send” on that milling job, double-check your contacts.

  You should also be considering the natural tooth anatomy and spacing to avoid overbuilding the crown.

• Test fit and adjust: After milling, do a dry-fit on the model.

  Use articulating paper to test the contact points.

  If it’s too tight, gently adjust it with your rotary instruments.

  If too loose, you might need to return to the design phase to bulk up the contact points.

4. Inconsistent Shade Matching – The Color Conundrum

Ah, shade matching.

Nothing screams “amateur hour” like a crown that looks great in the lab but sticks out like a sore thumb in the patient’s mouth.

Getting a perfect colour match is as much art as it is science, and it’s easy to miss the mark.

Why it happens: Poor lighting, inconsistent shade guides, or rushing the colour selection process can all contribute to crowns and bridges that don’t blend naturally.

How to avoid it:

• Invest in good lighting: Lab lighting is crucial. Natural light is best, but if you can’t get enough of that, invest in a quality colour-matching light source that mimics natural daylight.

• Consistent shade guides: Always use the same shade guide brand your dentist uses.

  Even subtle differences between guide systems can lead to mismatches.

• Customize the shade: When necessary, adjust the porcelain or composite with stains and glazes.

  Don’t be afraid to mix things up to match the unique nuances of each patient’s teeth.

5. Poor Finishing – The Rough Truth

So, your crown fits perfectly, and the shade is spot-on, but then there’s the finishing… or lack thereof.

A rough surface or over-polished crown can ruin an otherwise perfect job. It’s like putting together a beautiful car but skipping the paint job.

Why it happens: Poor finishing is often due to rushing or not using the right tools.

How to avoid it:

• Take your time: Finishing takes finesse.

  Use the proper burs and polishing tools for each material. Don't shortcut this step by thinking the dentist will "take care of it chairside."

• Polish, don’t over-polish: You want a smooth finish, but don’t go overboard. Over-polishing can make surfaces too smooth, leading to friction issues or poor wear performance over time.

  Find the sweet spot – smooth enough to feel comfortable, but not so slick that it causes functional problems.

Bonus Tip: Streamlining Production with GreatLab

You’ve made it this far, and by now you’re probably thinking, “This sounds like a lot to keep track of!”

And you’re not wrong.

Between managing materials, perfecting fits, and juggling shades, crown and bridge production can get overwhelming fast.

But here’s the good news: you don’t have to do it alone.

GreatLab, our all-in-one laboratory management system, is designed to take the stress out of managing the technical and administrative sides of your lab.

With GreatLab, you can track cases, manage inventory, automate workflows, and ensure that every step of your crown and bridge production is running smoothly.

Think of it as your lab’s personal assistant – minus the coffee breaks.

6. Handling Emergencies and Rush Orders – Don’t Panic, Plan

Lastly, nothing throws off your crown and bridge game like an emergency or rush order.

We’ve all had those frantic calls from the dentist asking, “Can you have this ready by tomorrow?” Sure, no problem. (Cue internal screaming.)

Why it happens: Miscommunication, lack of planning, or last-minute requests can create chaos in the lab, leading to rushed jobs and increased errors.

How to avoid it:

• Set realistic timelines: Be clear with your clients about how much time you need to deliver quality results. If the dentist wants it tomorrow, make sure they understand the risks of rushing.

• Keep organized with GreatLab: Our GreatLab system helps you keep track of all incoming orders, set realistic deadlines, and prevent overbooking.

  It’s like having an air traffic controller for your cases – making sure nothing crashes.

Final Thoughts

Crown and bridge production is a skill that takes time, patience, and constant improvement.

By avoiding these common mistakes, you’ll produce better results, save time, and reduce the stress that comes with reworking faulty restorations.

And don’t forget – when things get chaotic, GreatLab has your back.

It’s not just about managing your lab; it’s about mastering your craft and making sure every crown and bridge leaves your lab looking and fitting like a masterpiece.

Now get back in the lab and start crafting with confidence!

Thank you for staying connected with Dental Lab Tips.  We look forward to bringing you more exciting updates from the world of dental technology.