Why dental crown remakes happen: causes, costs and how to prevent them

Nobody wants to have to remake a dental crown. It means more time, more cost, and extra work for the dental team, while patients may need further appointments and have to wait longer for their treatment to be finished. Although some remakes can’t be avoided, many happen for reasons that can be identified and improved over time. 

Even a small number of dental crown remakes can have a bigger impact than many practices realise, disrupting busy schedules, reducing efficiency, and putting unnecessary pressure on both the practice and the dental laboratory. By understanding the crown remake causes and recognising common patterns, changes can be made on both sides to improve consistency, reduce costs, and deliver more predictable outcomes.

What counts as a dental crown remake?

A dental crown remake is any new crown that has to be made because the original restoration cannot be used as planned. This might be discovered before the crown is fitted or after it has been placed. If the original crown needs to be replaced rather than simply adjusted, it is generally considered a remake.

It is also important to tell the difference between a remake and a planned replacement. Crowns do not last forever, so replacing an older restoration as part of ongoing dental care is expected. A remake is different because it involves replacing a newly made crown that has not achieved the intended result.

There are many reasons why this can happen. A crown may not meet the expected standard, may not be suitable for fitting or may need to be replaced after placement. Identifying the reason for each remake helps practices understand where problems are occurring without making assumptions about the cause.

Recording and reviewing remakes over time can provide valuable insights. Looking for patterns makes it easier to spot areas for improvement, measure the impact of changes and support a more consistent approach to delivering high-quality restorations.

The clinical reasons crowns need to be remade

There are several clinical reasons why a dental crown may need to be remade. Sometimes the cause is obvious, but often it comes down to a combination of factors rather than a single mistake. Recognising these common challenges can help dental teams understand where things can go wrong and where small improvements can make a difference.

• Inadequate tooth preparation: A crown needs enough space and support to fit and function properly. If the tooth has not been prepared in a way that suits the chosen restoration, the final fit may not be successful.
• Poor impression quality or inaccurate scans: Whether using traditional or digital impressions, the information sent to the laboratory needs to be accurate. Missing details or distortions can cause crown fit problems.
• Incorrect shade selection: Matching the colour of a natural tooth can be challenging, and differences in lighting, shade assessment, or the information shared with the laboratory can all influence the final result.
• Occlusal and margin issues: A crown should fit comfortably and work naturally with the patient’s bite. If there are problems with the bite or the margins, the restoration may need to be remade to achieve a better fit.
• Soft tissue management challenges: Clear access to the preparation margins is essential when taking an impression or scan. Bleeding, moisture, or inflamed soft tissues can make it more difficult to capture the detail needed for an accurate restoration. 
• Patient-related factors that emerge after manufacture: A patient’s mouth can change between appointments. Small changes to the tooth, gums, or bite may mean a crown that was suitable when it was made no longer fits as expected by the time it is ready to be fitted. 

Every remake provides an opportunity to learn. Looking at the clinical factors behind each case can help practices improve consistency, reduce unnecessary repeat work and achieve more predictable results over time.

Laboratory and communication factors behind remakes

The quality of a dental crown depends on more than just the clinical work. The information sent to the dental laboratory, the way the crown is made and clear communication throughout the process all play an important role. Even small misunderstandings can sometimes mean a restoration needs to be remade.

• Manufacturing tolerances and production errors: Although laboratories have quality control measures in place, no manufacturing process is completely free from error. Small variations can occasionally affect the fit, function, or appearance of a crown.
• Material selection issues: Every restorative material has its own strengths and limitations. If the chosen material is not the best match for the clinical requirements, it may not deliver the expected outcome.
• Missing or unclear prescriptions: The laboratory can only work with the information it receives. If important details are missing or unclear, technicians may have to make assumptions, increasing the risk of the finished restoration not meeting expectations.
• Incomplete digital files or scans: Digital workflows depend on accurate, complete data, so missing scan information, poor-quality files, or other digital issues can make it more difficult for the laboratory to produce a precise restoration. 
• Shade communication problems: Achieving the right shade often relies on more than a single shade guide reference. Clear instructions and supporting information like shade maps and photographs help the laboratory understand the intended result and reduce the chance of colour mismatches.

Good communication between the dental practice and the laboratory helps bring all of these elements together. Sharing clear information, asking questions when needed and providing feedback throughout the process creates a stronger partnership and supports more consistent outcomes for every case.

The true cost of dental laboratory remakes

When a dental crown needs to be remade, the cost goes far beyond paying for another restoration. As well as the laboratory fee, there may be extra impressions or scans, additional materials and shipping costs. Each cost may seem small on its own, but they can quickly build up across multiple cases.

Time is another important factor. Every remake usually means another appointment, taking up chair time that could have been used for other patients. It also creates extra work for clinicians, nurses and administrative staff, making it more difficult to keep busy schedules running smoothly.

Patients are also affected by remakes. Having to come back for an extra visit can be inconvenient, especially if they need to take more time away from work or change existing plans. Although most patients understand that unexpected issues can happen, a longer treatment journey can still affect their overall experience. 

For dental practices, the combined effect of these costs can reduce profitability and make day-to-day workflows less efficient. Remakes can also influence how patients view the quality of care they receive, which is why reducing avoidable remakes benefits both the practice and the people it treats. 

How dental practices and laboratories can reduce crown remakes

Reducing dental crown remakes is usually the result of lots of small improvements rather than one major change. When dental practices and laboratories work together and follow consistent processes, it becomes easier to achieve reliable results and reduce avoidable repeat work.

A good place to start is with clear preparation and scanning protocols. Taking the time to check that preparations are suitable and that impressions or digital scans capture all the necessary detail can help prevent problems from being carried through to the next stage. Providing a complete laboratory prescription is equally important, giving technicians the information they need to produce the restoration with confidence. 

Digital workflows can also help by making it easier to review cases and identify missing information early before production begins, while following a consistent approach to shade communication helps reduce uncertainty. Regular feedback between the dental practice and the laboratory creates opportunities to learn from both successful cases and remakes, and looking at trends over time also supports continuous quality improvement. 

At the heart of it all is a strong working relationship between the dental practice and the laboratory. Open communication, shared expectations and a willingness to learn from every case help build trust on both sides and create the best conditions for delivering consistent, high-quality restorations.

Reducing crown remakes starts with collaboration

Reducing dental crown remakes is not about finding a quick fix. It comes from paying attention to every stage of the process and making sure everyone involved is working towards the same outcome. When the dental practices we work with at GoDigital Dental communicate well and follow consistent ways of working, it becomes much easier to deliver predictable, high-quality results.

There will always be situations where a remake cannot be avoided, but many can be reduced by learning from previous cases and making small improvements over time. Looking at what works well, as well as where things could be done differently, helps build a stronger and more reliable workflow.

Ultimately, responsibility for the final outcome rests with the dental practice. By combining good clinical judgement with clear communication and a collaborative relationship with the laboratory, practices can reduce avoidable remakes and provide a better experience for every patient.

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