Resolution Is Power — But Power Has a Cost

Higher scan resolution promises sharper margins and finer occlusal detail. But it also generates larger files, longer processing times, and heavier storage demands.

At Repair.Dental, we often see labs default to maximum resolution “just to be safe.” In reality, this habit quietly reduces workflow efficiency and inflates IT costs.

Resolution should be strategic — not automatic.

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What Scan Resolution Really Changes in Daily Production

Resolution affects three operational factors:

Surface detail density
Processing time
File size and storage load

Higher density captures more points per millimetre.
That improves detail in complex cases — but slows reconstruction and consumes storage.

Not every case requires maximum precision.

When High Resolution Adds Value — And When It Doesn’t

Understanding case complexity prevents unnecessary data overload.

Cases That Benefit from Higher Resolution

Implant-supported restorations
Full-arch prosthetics
Thin feather-edge preparations
Highly detailed occlusal anatomy
Complex multi-unit bridges

Cases Where Standard Resolution Is Sufficient

Single posterior crowns
Diagnostic models
Temporary restorations
Opposing arch scans
Study models

Using high density on low-risk cases adds little clinical value — but increases digital weight.

Comparing Resolution Levels: Accuracy vs File Impact

Resolution Level	Average File Size (Single Crown)	Processing Time	Clinical Accuracy Impact
Standard	40–60 MB	Fast	Clinically sufficient
High	80–120 MB	Moderate	Improved margin clarity
Maximum	150–250 MB	Slower	Necessary for complex cases

Multiply these numbers across hundreds of monthly cases.

Storage expands quickly.
So does processing delay.

The Hidden Storage Costs Labs Often Overlook

Digital storage is not free — even in cloud environments.

Excessive file sizes lead to:

Increased server requirements
Slower backups
Longer data transfers
Sluggish CAD loading times
Higher cloud subscription costs

IT infrastructure quietly absorbs unnecessary expense when resolution settings are unmanaged.

Precision should not compromise operational sustainability.

Workflow Impact: Speed vs Detail Balance

Higher resolution also influences real-time production.

Effects include:

Longer scan capture time
Extended reconstruction cycles
Increased CAD file loading delay
Slower archive retrieval

When multiplied across technicians, even 60 seconds per case affects daily output.

A 10-case-per-day technician saving one minute per case regains nearly a full working hour per week.

Efficiency compounds.

Smart Resolution Allocation: A Practical Framework

Instead of universal maximum settings, adopt targeted resolution policies.

Suggested Internal Guidelines

Default to Standard for routine single-unit cases
Use High for multi-unit bridges
Reserve Maximum for implant and full-arch cases
Apply adaptive density if supported by software

Resolution should follow clinical need — not habit

Storage Reduction by 38%

One mid-sized lab experienced slow network performance.
File sizes averaged 180 MB per case due to default maximum resolution.

After reviewing resolution policies:

Standard cases shifted to lower density
Maximum resolution limited to 15% of cases
Monthly storage growth reduced by 38%
Scan-to-design time improved noticeably

Their feedback:

“We thought more data meant better quality. Smarter data improved both speed and storage control.”

Optimisation delivered measurable ROI.

How Resolution Affects Long-Term Data Management

Consider a lab scanning 1,200 cases per month.

If average file size drops from 180 MB to 90 MB:

Monthly storage savings = ~108 GB
Annual savings = ~1.3 TB

Multiply that across multi-year retention policies.

Storage strategy becomes a financial decision — not just a technical one.

Improving Performance Without Sacrificing Accuracy

Resolution optimisation should not reduce prosthetic quality.

To maintain precision:

Verify calibration before lowering resolution
Use margin-enhanced capture zones
Apply selective high-density scanning for prep areas only
Review mesh quality before finalising

Selective detail often outperforms blanket maximum settings.

Control improves confidence.

Performance Indicators to Monitor

Resolution strategy should be measurable.

Track:

Average scan time per case
CAD loading time
Monthly storage growth
Remake rate
Margin correction frequency

If remake rates rise after lowering resolution, reassess settings.

Optimisation must support — not compromise — clinical results.

Avoiding Common Resolution Mistakes

Even experienced labs can mismanage resolution settings.

Avoid:

Using maximum density for every scan
Ignoring IT storage trends
Failing to train technicians on case-based resolution selection
Overlooking adaptive scanning features
Confusing file size with clinical precision

More data does not automatically equal better results.

Relevant data delivers better results.

The Strategic Value of Resolution Management

Balancing resolution and storage delivers:

Faster scan cycles
Lower IT costs
Improved network performance
Reduced data backup times
More predictable workflow

Operational efficiency improves when digital weight is controlled.

Smart configuration supports sustainable growth.

The Repair.Dental Perspective: Optimise for Performance, Not Excess

Resolution is a powerful tool.
But unmanaged resolution inflates cost without proportional benefit.

By implementing case-based resolution policies, monitoring storage trends, and reviewing performance metrics, labs can:

Increase technician productivity
Reduce storage expansion costs
Maintain clinical precision
Improve overall turnaround time

At Repair.Dental, we emphasise intelligent optimisation over default settings.

Because efficiency is not about collecting more data.

It is about collecting the right data — at the right time — for the right case.

And when resolution is balanced strategically, workflow accelerates, storage stabilises, and profitability improves.

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Scan Resolution Settings: Storage vs Quality Trade-offs