Written by: Dr. Russell Shafer
INTRODUCTION
As new solutions emerge to enhance comfort, aesthetics, and patient turnaround time, incorporating digital dentistry has revolutionized the approach to removable prosthodontics. The adoption of cutting-edge technologies such as intraoral scanners, design software, and 3D printing enables dental professionals to deliver highly customized, precisely manufactured dentures in fewer visits. These advancements offer many benefits to patients and clinicians, including improved fit, reduced chair time, and the ability to quickly reproduce prostheses using saved digital records.
Traditional denture workflows require numerous manual steps, including articulation, wax try-ins, and adjustments by hand. Digital solutions streamline this process by reducing variables that often lead to inaccuracies. Patients benefit from enhanced aesthetics and functionality, while clinicians gain improved control over case design and denture reproducibility. This case study demonstrates how a fully digital workflow can produce a 3D printed complete denture with exceptional results.
CASE PRESENTATION
A 62-year-old female presented for evaluation after several years of wearing a complete denture previously fabricated by the author. The prosthesis showed signs of wear and had become ill fitting (Figure 1). Her original denture, made approximately 3 months post full-mouth extractions, had served her well aesthetically. However, she noted that the prosthesis no longer fit adequately, causing discomfort and instability during everyday use.
Despite the poor fit, she remained satisfied with the overall shape, size, and alignment of her teeth. Her primary concern was retention, followed by a desire for a brighter, more youthful shade. Clinical examination confirmed that her vertical dimension of occlusion (VDO) remained stable and could be replicated in a new prosthesis (Figures 2 to 3). With the patient’s priorities identified and baseline records confirmed, the team initiated a digital workflow to fabricate her replacement denture.
CLINICAL WORKFLOW
Impression and Bite Registration
To preserve the successful elements of the previous denture while improving the fit, the existing prosthesis was used to take a reline impression. Polyvinyl siloxane (PVS) adhesive was applied to the intaglio surface, followed by a fast-set light-body PVS material (Figure 4). A blue bite registration (Nice Bite [Safco]) was also recorded to establish centric relation. This approach provided a predictable foundation for digital modeling while retaining familiar contours and occlusal characteristics.
Intraoral Scanning and Design
The relined denture was scanned with a Medit i500, generating a digital model that preserved the patient’s preferred tooth arrangement and occlusal scheme. These files were sent to Mr. Seth Potter, a skilled dental technician, who used exocad software to design the final prosthesis. The resulting design (Figure 5) featured carefully replicated anatomy with slight enhancements to improve incisal display and lip support.
Modern design software with integrated virtual articulation tools enabled precise evaluation of functional occlusion in a fully digital environment. This allowed for detailed refinement of the occlusal surfaces to optimize contact and performance. Targeted adjustments were made to ensure balanced articulation and stable posterior support—both critical factors in a case with limited residual ridge anatomy.
Try-In Fabrication and Evaluation
A monolithic 3D printed prototype was fabricated from the finalized digital design, enabling both the clinician and patient to assess fit and aesthetics in real time (Figure 6). The use of 3D printing allowed for the accurate reproduction of anatomical detail, and the prototype was polished to closely mimic the appearance of the final restoration. The patient was satisfied with the improved comfort and aesthetic outcome, and no significant adjustments were necessary.
Final Denture Production
Following the successful try-in, the confirmed digital design was used to fabricate the new denture. The workflow included separate printing of the base and tooth components to optimize aesthetics and mechanical performance (Figure 7). Post-processing involved removal of supports and cleaning with isopropyl alcohol prior to final curing.
Rodin Glaze N2-Free was selected for its unique ability to chemically eliminate the oxygen inhibition layer, allowing for efficient polymerization without the need for a nitrogen-curing environment or manual polishing. This workflow served a dual role: first, as a bonding agent between the denture base and tooth segments, and second, as a final surface glaze. A thin layer of glaze was applied at the interface to create a strong chemical bond without requiring additional adhesives. Once assembled, the excess glaze was applied to the external surfaces of the denture, producing a protective, high-gloss finish while preserving anatomical detail and enhancing patient comfort.
The final denture was printed using Rodin Denture Base 2.0 (Pac-Dent) for the gingival base and Rodin Titan (Pac-Dent) for the teeth (Figure 8). This material combination was selected for its aesthetic appeal, high strength, and durability. Denture Base 2.0 offered excellent anatomical reproduction, while Titan provided lifelike translucency and wear resistance. Comparable materials in these categories may also be considered, depending on clinical preferences and printer compatibility.
Delivery
The final denture was delivered at a follow-up visit, where it was carefully evaluated for fit, occlusion, and aesthetics. The prosthesis demonstrated excellent tissue adaptation and required only minimal adjustment. The patient expressed immediate satisfaction with the comfort and natural appearance of the restoration (Figures 9 and 10), noting that the brighter aesthetics contributed to a more confident smile.
DISCUSSION
This case highlights the value of a fully digital workflow in complete denture fabrication, particularly when using a reference denture approach. By digitally capturing the patient’s existing prosthesis, the clinical team preserved familiar aesthetics while making functional improvements through intraoral scanning, CAD design, and 3D printing. This method significantly reduced reliance on traditional, labor-intensive steps such as physical impressions, stone model fabrication, articulation, and wax set-ups, allowing for a more precise and efficient treatment process.
The ability to fabricate a 3D printed try-in further streamlined the workflow, eliminating conventional trial procedures and enabling rapid patient feedback without compromising aesthetics or detail.Once validated, the design could be finalized and reprinted with precision, ensuring consistency across appointments. Additionally, digital file storage provides long-term value by supporting easy remakes, refinements, or reprints. Compared to traditional workflows, this approach offers reduced variability, improved clinical and laboratory efficiency, and a more scalable, patient-friendly solution.
CONCLUSION
As digital denture technology evolves, it will continue to empower clinicians, allowing them to provide aesthetic, functional, and predictable outcomes through a streamlined, patient-centered workflow. By replacing analog steps with digital processes and preserving design files for easy modification, practitioners shorten the turnaround time, enhance control over occlusion and aesthetics, and offer greater long-term flexibility. As these technologies become routine, digital removable prosthodontics will transform denture fabrication—delivering consistent, personalized results with greater efficiency and precision.
ABOUT THE AUTHOR
Dr. Schafer is a general dentist in New Orleans, La, and owner of NOLA Dentures and General Dentistry, where he focuses on removable prosthodontics and has restored countless smiles with dentures. Passionate about the field, he teaches fellow dentists about removable workflows and is deeply involved in digital dentistry, with extensive CAD experience in Blue Sky Plan, Meshmixer, and other software. An avid 3D printing user, he owns 7 printers and integrates digital tools into daily practice. Originally trained as an engineer, he earned BS and MS degrees in mechanical engineering from Rice University before graduating from LSU School of Dentistry in 2013. He can be reached at russell.schafer.dds@gmail.com.
Disclosure: Dr. Schafer received compensation for lab work from Pac-Dent but did receive compensation for writing this article.
