📘 CEREC Troubleshooting Guide

Overview

Sirona CEREC systems are powerful, but certain issues can prevent clean exports, accurate scans, or successful uploads to CAE Dental. This guide lists the most common problems clinicians encounter — and exactly how to fix them quickly.

⚠️ Common CEREC Issues & How to Fix Them

1. CEREC Won’t Export STL Files

Symptoms

• “Export failed”
• STL option missing
• Export button grayed out

Causes

• Wrong workflow selected
• Case not finalized
• Software version too old
• Export permissions disabled

Fix

• Complete the entire scan workflow
• Go to Administration → Export
• Select Model (STL)
• Update CEREC software if STL export is missing
• Restart the software if the export button is frozen

2. Bite Scan Doesn’t Export or Is Missing

Symptoms

• Only upper/lower STL exported
• Bite file not generated

Causes

• Older CEREC versions don’t export bite STLs
• Bite scan not captured correctly
• Bite not finalized

Fix

• Ensure bite scan is captured in the workflow
• If your version doesn’t export bite STLs:
  → Upload upper + lower only
  → CAE Dental will align manually
• Update to a newer CEREC version if possible

3. Scan Bodies Not Showing Clearly in the STL

Symptoms

• Scan body looks distorted
• Missing edges or incomplete geometry
• Implant position inaccurate

Causes

• Scan body not fully seated
• Wrong scan body brand
• Shadows or stitching errors
• Scanned too quickly

Fix

• Remove and reseat scan body
• Verify correct brand/model
• Dry the area before scanning
• Capture all surfaces slowly
• Re‑scan the implant region if needed

4. Holes or Missing Anatomy in the Scan

Symptoms

• Gaps in the arch
• Missing cusps or margins
• Tissue not captured

Causes

• Fast scanning
• Poor angulation
• Reflective surfaces
• Software stitching errors

Fix

• Re‑scan missing areas with slow, steady passes
• Tilt scanner to capture undercuts
• Ensure the field is dry
• Trim excess data and re‑capture problem zones

5. Bite Doesn’t Line Up With Upper/Lower Scans

Symptoms

• Occlusion looks off
• Bite appears shifted
• Arches don’t align in STL viewer

Causes

• Patient not fully closed
• Bite captured only on one side
• Distorted bite scan
• Excess saliva or movement

Fix

• Re‑capture bite with bilateral contact
• Have patient close in centric relation
• Dry occlusal surfaces
• Capture 3–5 seconds of stable contact

6. STL Files Won’t Upload to CAE Dental

Symptoms

• Upload fails
• “Unsupported file type”
• File too large

Causes

• Wrong file format (e.g., proprietary CEREC format)
• File names contain special characters or PHI
• File size too large

Fix

• Ensure files are .stl
• Rename files to:
  • Upper.stl
  • Lower.stl
  • Bite.stl
• Zip large files before uploading
• Remove patient names from filenames

7. CEREC Freezes or Crashes During Export

Symptoms

• Software locks up
• Export window freezes
• CEREC restarts

Causes

• Large case files
• Low system memory
• Software bug

Fix

• Restart CEREC
• Export one file at a time
• Clear old cases from the system
• Update to the latest CEREC version

8. STL Files Look “Jagged” or Low Quality

Symptoms

• Rough surfaces
• Pixelated anatomy
• Poor margin clarity

Causes

• Fast scanning
• Low‑resolution export settings
• Excess saliva or debris

Fix

• Re‑scan margins slowly
• Dry the area thoroughly
• Ensure scanner tip is clean
• Update scanner calibration

🧪 Quick Quality Checklist Before Exporting

✔ Upper arch complete

✔ Lower arch complete

✔ Bite captured bilaterally

✔ No holes or missing anatomy

✔ Scan bodies fully seated (implants)

✔ Files named simply (Upper/Lower/Bite)

✔ STL exported — not proprietary format

🚀 Tips for the Best CEREC Results

• Move slowly around margins and scan bodies
• Capture vestibules and palate fully
• Use PLY only if your CEREC version supports it
• Keep scanner tip clean and dry
• Re‑scan problem areas instead of relying on stitching
• Always verify STL files in a viewer before uploading