Digital Impression Error Checklist: Preventing Artifacts, Distorted Margins, and Scan Voids

Digital dentistry continues to evolve, and intraoral scanners have become essential tools for efficient, accurate restorative workflows. Yet even the best technology can only perform as well as the data it receives. At Upper Valley Dental Laboratory, many remake requests stem from a handful of recurring digital impression errors, issues that are easy to overlook chairside but highly impactful once the case reaches the lab.

This educational checklist outlines the most common digital impression problems that lead to rejections or compromised restorations. By integrating these review steps into your scanning protocol, your team can dramatically reduce remake rates and ensure predictable, high-quality outcomes.

1. Margin Distortion or Incomplete Capture

Margins are the foundation of every crown, bridge, or onlay. When they are distorted, pixelated, or partially missing, the lab cannot design a restoration with an accurate fit.

Typical causes include:

• Insufficient tissue retraction
• Moisture obscuring the finish line
• Scanner tracking loss around deep or subgingival margins

Before submitting a scan, zoom in on each margin. Look for smooth, continuous lines without waviness or “melting.” If any area appears unclear, isolate and rescan that region rather than repeating the entire arch.

Clinical tip: Dual-cord retraction or retraction paste significantly improves clarity for challenging margins.

2. Scan Voids and Missing Data

Scan voids appear as holes, gray patches, or unscanned surfaces. These gaps often occur on occlusal grooves, interproximal contacts, or lingual surfaces, areas that scanners can miss if the angle or lighting is inconsistent.

Common causes include:

• Moving too quickly over reflective enamel
• Shadows from cheeks, tongue, or lips
• Irregular scanning patterns

Rotate the digital model in your software to inspect every surface. If you see missing texture or incomplete anatomy, fill those areas before sending the case.

3. Artifacts from Saliva, Blood, or Scanner Drift

Artifacts are false shapes or streaks that do not match natural tooth anatomy. They can distort occlusion, create false contacts, or alter tooth contours.

Artifacts typically result from:

• Excess saliva pooling
• Scanner drift from rapid movements
• Overlapping scans confusing the software

Dry the field thoroughly and perform a slow, controlled cleanup pass to eliminate unwanted data.

4. Inaccurate Bite Registration

Even perfect arch scans can be rejected if the bite is incorrect. Labs frequently encounter:

• Posterior open bites
• Cross-arch mismatch
• Bite scans taken with the patient not fully closed

Confirm that both sides show consistent contact and that the bite aligns naturally with the patient’s habitual occlusion.

5. Over-Scanning and Excess Data

Too much redundant data can cause stitching errors or slow processing. Follow a structured scan path and avoid repeatedly scanning the same area unless correcting a void.

A consistent digital impression review protocol is one of the most effective ways to reduce remakes and improve restoration accuracy. Upper Valley Dental Laboratory is committed to supporting your digital workflow with resources that strengthen clinical-lab collaboration.

Digital Dental Lab Support in Rexburg, ID

Upper Valley Dental Laboratory helps dental practices improve digital workflows with reliable CAD/CAM support, high-quality restorations, and experienced lab collaboration. Whether your team is troubleshooting scan issues, submitting digital impressions, or looking for a dependable partner for crowns, bridges, implants, and other restorative cases, our team is here to help. We proudly serve dental practices in Rexburg, Ammon, Idaho Falls, Chubbuck, and throughout Idaho with personalized service and advanced dental laboratory solutions. Contact us today to learn more about our digital workflow support or submit your next case.