What is the best method to achieve a satisfactory fit of a crown casting that is open in the mouth?

The most effective method to achieve a satisfactory fit of a crown casting that is open in the mouth is to make a new impression and remake the crown. This approach ensures that the crown accurately matches the contours and position of the prepared tooth. A new impression captures the current state of the tooth and surrounding structures, accommodating any changes that may not have been present during the initial impression or fabrication of the crown.

While techniques such as burnishing (both hand and mechanical) can help modify the fit of the crown to some extent, they often do not provide the precision required for a proper fit. They can sometimes only help in minor adjustments rather than addressing more significant discrepancies. Additionally, relieving the occlusal surface of the crown helps with occlusion adjustments but does not guarantee an overall satisfactory fit, as it does not correct the underlying shape or retention issues associated with the original impression. Hence, remaking the crown based on a new impression is considered the most reliable method to achieve the desired fit.