Digital Alignment Accuracy of Zirconia Abutments Using Library Data on Incompletely Captured Implant Impressions: An In Vitro Study; [Eksik Dijital İmplant Ölçülerinde Zirkonya Abutmentlerin Kütüphane Verisi ile Dijital Eşleştirme Doğruluğu: İn Vitro Çalışma]

Objectives: This in vitro study aimed to evaluate the feasibility and accuracy of digitally aligning zirconia customized abutment library files onto incomplete abutment scan datasets. Superimposition was compared to the conventional “Close holes” reconstruction function in computer-aided design (CAD) software. Materials and Methods: A single-implant dental model was used, and a custom zirconia abutment was scanned to generate a digital library file. Complete scans of the abutment and adjacent teeth served as the control group (C). Two experimental datasets were produced by selectively deleting marginal regions (NC2) and both marginal and proximal surfaces (NC3) from the complete scan. Defective scans were processed either by digital superimposition with the abutment library file (S group) or by applying the “Close holes” function in CAD software to reconstruct missing areas (CH group). All datasets were analyzed in Geomagic Control X (3D Systems, USA) to assess trueness using root mean square (RMS) error and point-based deviation analysis. Statistical evaluation was performed using one-way ANOVA and Tukey HSD post hoc tests Results: Superimposition significantly improved trueness compared with unprocessed scans. RMS values decreased from 39.11 ± 0.98 μm in the IOS (intraoral scanner) group to 35.41–37.59 μm across the C, NC2, NC3, and S groups datasets (p = 0.032). The CH group showed significantly higher deviations than all superimposition groups (p < 0.001). Point-based analysis confirmed lower deviations after superimposition (p = 0.008). No significant differences were found among the superimposed groups. Conclusions: Digital superimposition of zirconia abutment library data onto incomplete scans enhances trueness and geometric reliability. This method is superior to conventional reconstruction tools for restoring incomplete implant impressions. © 2025, This work is licensed under Creative Commons Attribution 4.0 International License.