Has anyone got a proven calibration/verification bundle for the scan-CAD-CAM-mill chain? I’m tuning exocad Galway + hyperDENT on a vhf S5 and seeing 18–22 µm trueness on a step gauge but inconsistent occlusal contact; I’m after STL artifacts and a measurement protocol (ISO 12836/VDI 2634) you trust.
On my S5 I pinned occlusal consistency by using a two-piece coupon (base with three 4 mm bosses + a cap with a 12 mm flat): mill in PMMA, scan-back, best-fit on the bosses only, then nudge hyperDENT’s finish tool radius comp by -0.01 mm until 8–12 µm shimstock just drags; compare in CloudCompare (https://www.cloudcompare.org). I can share the STL pair and a one-page ISO 12836 scan-back note — want it?
Before STL checks, run a QC20 ballbar on the S5: QC20 ballbar for machine tool verification — fixed my occlusal drift; you lock shrink factor per lot?
Try a 3‑sphere plate paired with a split‑occlusal coupon: mill both in the same puck, align only on the spheres, then “fit spheres, measure center distances” per VDI 2634 and record Z‑only occlusal deltas in hyperDENT — this cleanly separates scale error from tilt. @martinB_76 your bosses idea pairs well, but spheres reduce plane bias; I can share the STL set if you want. It’s like tuning a guitar — once the reference is true, the bite stops singing off‑key.
I hate when hand signals disappear under the drape, so during your 30‑second rundown I tell them, “If you need a pause, roll your left shoulder and I’ll see it,” and I prove it while I do the quick suction test. It gives control without tying up hands and hasn’t slowed my surgeon at all. A shoulder cue still works even with the throat pack.
I’d validate your occlusion by first calibrating the finishing tool’s effective radius with a slot‑width STL (e.g., three slots at 1.000/1.050/1.100 mm); cut, mic them, then tweak hyperDENT until the 1.000 reads true (I usually end up around “finish tool comp: +6 µm”). After that, run a checkerboard clearance coupon with 10/20/30 µm pads to see if contacts normalize — I can share that STL if you want. Do the cuts in the same material lot and tool set to keep variables tight.