Split one hybrid into a bar and a superstructure
Split Bar takes a finished all-on-X hybrid and separates it into the two pieces you actually manufacture: the bar that carries the implant interfaces, and the superstructure that seats over it. The screw channels stay clear through the cut, and the cement space between the pieces is yours to set.
Everything is computed in your browser, so it responds immediately and nothing waits in a queue. The heavy steps spread across up to 8 worker threads, one fewer than the cores they find, and the result is identical at any thread count. Where threading is unavailable the same single-thread engine runs instead: same geometry, more time.
The workbench measures and shows; it does not certify. Check both finished pieces yourself, and verify them against your production process before clinical use.
Work through the six steps in order
Orientation
Confirm which way the occlusion faces. The panel reports the measured tilt in degrees and offers to level the scan; a scan that arrives upside down is turned over here. Nothing else unlocks until orientation is confirmed.
Implant sites
Place a site on each implant interface. This is what tells the design where the screw channel has to stay clear. All-on-X cases usually carry four to eight implants, and the panel says so when it sees fewer than four. Each site also carries a protection band, 0.2 to 3 mm and 0.35 mm unless you change it, which keeps the bar off the interface itself.
Margin line
Draw the closed outline that limits the bar. It has to close back on its start point before the next step opens. The panel warns when a site has less room between its screw channel and your line than the wall and the ledge together need, and it names the site.
Form
Choose the base form and shape the bar. Classic is the general form; Strip is for FP1 work and needs at least two implant sites, otherwise it builds as Classic. Height runs 0.1 to 30 mm from 0.5 mm, the finish ledge 0.5 to 1.2 mm from 0.55 mm, the bar angle 0 to 24 degrees from 0, and the two shrink controls take 0 to 2 mm out of the middle and 0 to 1 mm off each side, both from 0. On Strip you also set the bar width, 1.5 to 4 mm from 2.5 mm, and the section height, 1.5 to 6 mm from 3 mm.
Refine
Set the cement space, check the wall, and sculpt what needs it. The field gap runs 0.05 to 0.5 mm from 0.2 mm and the seal gap at the margin 0.05 to 0.2 mm from 0.1 mm, never wider than the field gap, over a seal band of 0 to 3 mm from 1 mm. The minimum wall runs 0.4 to 2 mm from 0.8 mm, and the panel reports what percentage of the surface is thinner than that, showing it in red. The cut itself already leaves 0.05 mm between the pieces, so that is the floor for any gap.
Result
Run the split, then look at both pieces. Download them as two model files, or as a package with the bar, the superstructure and the CAM file together. The workbench prints no pass badge on purpose: it gives you the measurements and you make the call.
Prepare the scan and the sites
The bar is designed against the hybrid itself, so the module takes one merged arch. Uploading two separate arches will not start a Split Bar case. A jaw scan can be attached as optional reference geometry; it is only ever drawn for context and never enters the design.
Export the hybrid as a single merged mesh, ideally with your CAD application's adapt for 3D printing option. Meshes exported without it tend to carry small surface defects that show up later as rough shaft walls.
That is the units check: the arch measured outside the 30 to 90 mm span a real jaw occupies, which almost always means the export was not in millimetres. It is a warning and not a block, so you can carry on, but re-export in millimetres before you rely on any measurement.
Yes. The implant interfaces and the screw channels are preserved through the cut, which is the point of designing against the hybrid rather than a plain arch. If a channel cannot pass cleanly through the bar, the build stops and names the site instead of closing it.
At least one support before a bar can be built, and in practice four to eight on an all-on-X case. The Strip form needs at least two sites, because it runs its spine between them.
Work in the browser without losing anything
The design and the cut are computed in your browser, which is why they respond immediately and why a slower machine feels it. Your draft is saved to the case as you work.
Yes. The draft saves locally within a second and to the case a couple of seconds later, so you can reopen the case and carry on from the step you were on. The newer of the two copies wins when they differ.
Ctrl+Z undoes your most recent edit, whichever step you are standing on now, so an edit made on an earlier step is still reachable after you move on. History is kept per step, up to 50 entries each, and edits made within a fraction of a second of each other are collapsed into one.
Yes, through save points. The workbench takes one automatically at each milestone, such as orientation confirmed, cut line closed, preliminary bar created, or final split done, and keeps the last 10 of those per case. Save points you take yourself are kept indefinitely. A restore is all or nothing: if a stored piece of geometry is missing, it tells you instead of restoring something half true.
Turn on the wall thickness probe and click the model. It answers for that point, and tells you when there is no wall behind the point or the surface there is too degenerate to measure.
The bar, the superstructure and a design report. Download the two pieces as model files, or take the package that also carries the CAM file.
Work through a build that will not finish
The outline you drew does not finish where it started, so there is no inside and outside for the cut to work between.
Carry on drawing until the line meets its own start point, then continue to the next step.
The bar is too low or too tight around that site for its channel to stay open.
Raise or reshape the bar around the site the message names, or measure the site again. If it repeats on a site that looks correct, send us the case number.
Shaping or sculpting has pushed the surface through itself somewhere, and no clean solid can be cut out of that.
Return to shaping and smooth that area, then build again. Restore an earlier save point if the area is hard to find. If it persists, send us the case number.
The two pieces did not come apart as one solid each, most often where the ridge is undercut or an implant sits close to the wall.
Review the implant sites and the local bar height, widen the field gap slightly, then build again. Your edits are kept. If it still holds together, send us the case number and we will look at the geometry.
The whole design and cut run on your own machine, so a large mesh on a modest laptop is genuinely doing hard work locally.
Close other heavy browser tabs and work on the machine with the most CPU cores, since the heavy steps spread across up to 8 threads. The system requirements page has the detail.
Roughness in the shafts usually comes from the scan rather than the cut, and it tracks the surface quality of the file you uploaded.
Re-export the hybrid as one merged mesh with adapt for 3D printing, which cleans the mesh up before it ever reaches us. If a re-export looks the same, send us the case number.