Application of the full digital workflow in immediate removable partial denture: an innovative case report

Abstract

Background. The fabrication of immediate removable partial dentures (RPDs) is characterized by the integration of digital technologies that enhance precision and efficiency in prosthodontic care. The application of a full digital workflow in this context is increasingly recognized for its potential to address both functional and esthetic needs of patients. The estimated prevalence of immediate RPDs in clinical practice is rising, yet literature exploring their digital fabrication remains limited. To our knowledge, this case report presents one of the first instances of utilizing a comprehensive digital approach for the creation of immediate RPDs, highlighting its benefits in patient outcomes. Case report. A 62-year-old male patient with maxillary anterior incisors mobility opted for immediate RPD treatment due to functional pain and esthetic concerns. Intraoral scanning was employed for impression taking and occlusion registration, generating Standard Tessellation Language files. Cone beam computed tomography provided Digital Imaging and Communication in Medicine (DICOM) files, enabling precise virtual extraction of the incisors and ridge smoothening using Exocad software. The denture design, teeth mounting, and surgical guide were digitally planned based on digital smile design outcomes. Digital light processing was utilized for prosthesis manufacturing, and assembly followed a detailed protocol outlined in the present paper. Post-extraction, regular follow-up sessions are essential to assess patient satisfaction. Conclusions. The integration of intraoral scanning and Computer-Aided Design and Manufacturing CAD/CAM technology offered a promising solution for the rapid production of immediate RPDs with enhanced accuracy and reproducibility. The successful assembly and long-term durability of 3D printed dentures were achieved through strategic design considerations and meticulous data processing.