Statement of problem. The construction of precise fixed prostheses that are harmonious within the stomatognathic function has been regarded as a critical requirement for successful oral rehabilitation. However, techniques for construction have been unsuccessful in producing a prosthesis that can be inserted without intraoral occlusal adjustment. Purpose. In this study, a new method of constructing a precise prosthesis that requires limited occlusal adjustment at the final seating is described. Material and methods. The precision of this method was compared with a conventional method. Fourteen artificial crowns were fabricated on an experimental abutment by using both double-casting and conventional methods. The distances between the cusp tips and occlusal surfaces of the abutments, which were measured on wax/resin patterns and resultant crowns, were recorded to estimate clinical error for each method. Results. Error for the double-casting method was markedly less than the conventional method. This study demonstrated that a new double-casting method was precise and sufficiently reliable for clinical application. (J Prosthet Dent 1998
79:120-24.). © 1998 Editorial Council of The Journal of Prosthetic Dentistry.