5-Axis Milling Benefits

Written By Max McLennan

Nexus frameworks come directly from Osteon Medical’s production facilities located in Melbourne, Australia and Irvine, USA. Both facilities specialize in precision milling of full-arch dental frameworks, predominantly, the innovative Nexus Hybrid style superstructures.

The machines used for all framework production in these facilities are known as 5-axes milling machines. For an understanding of scale and stability, these milling machines weigh from 2,000kg to 5,000kg.

Osteon Medical Melbourne's industrialised machining center.

Some of the major benefits of using 5-axes machines include:


Precision and Accuracy

  • Enhanced Detail: 5-axes milling allows for more intricate designs and precise adjustments, crucial for the fit and functionality of dental implant prosthetics.

  • Tighter Tolerances: These machines can achieve tighter tolerances, resulting in better-fitting prosthetics, which can reduce the risk of complications. Correctly calibrated 5 Axes machines have a positional accuracy of 10µm and a repeatability of 8µm. With a surface quality of Ra <0.1µm.

Material Versatility

  • Broader Material Range: Large 5-axes machines can handle a wider variety of materials, including advanced composites and metals.

  • Better Surface Finish: The advanced technology provides superior surface finishes, enhancing both aesthetic and functional properties.

Two Nexus bars milled from a single titanium disc. Precision of the digital setup and milled outcome.

Complex Geometry

  • Ability to Create Complex Designs: 5-axes milling is ideal for creating complex geometries that might be challenging for smaller machines, such as undercuts and intricate contours.

  • Custom Solutions: Enables customization for individual patient needs, improving the overall effectiveness of dental restorations.

Increased Productivity

  • Higher Efficiency: Large 5-axes machines can complete multiple processes in a single setup, reducing production time.

  • Less Downtime: More robust and reliable, these machines typically experience less downtime compared to smaller units.

Post-milled disc, returned to the pallet, ready for collection.

Automation and Integration

  • Advanced Automation Options: Many large machines offer automation features that streamline workflows, reducing manual intervention and improving consistency.

  • Seamless CAD/CAM Integration: These machines often have better compatibility with CAD/CAM software, facilitating a smoother transition from design to production.

Scalability

  • Ability to Scale Production: As demand for prosthetics increases, larger milling machines can accommodate higher production volumes without sacrificing quality.

  • Future-Proofing: Investing in advanced technology allows for easier upgrades and adaptations to future dental technologies and techniques.

Straight off the machine, ready for hand-polishing and preparation.

Robust Build Quality

  • Durability and Longevity: Large machines are generally built to higher standards, providing greater durability over time, which can be cost-effective in the long run.

  • Reduced Wear and Tear: Better construction materials and engineering reduce wear and tear, leading to consistent performance.

Improved Workflow

  • Fewer Setup Changes: Large machines often require fewer setup changes for complex jobs, saving time and reducing the potential for errors.

  • Streamlined Processes: Integration of multiple manufacturing steps in one machine reduces the complexity of the workflow.

While smaller milling machines may be more cost-effective initially, large 5-axes milling machines offer significant advantages in precision, material versatility, productivity, and overall quality in dental implant prosthetic production. These benefits can ultimately lead to better patient outcomes.

Max McLennan
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Nexus Prosthetic Concept