Clinical Implementation of a Fully Digital Workflow for the Fabrication of a Maxillary Complete Denture: A Case Report

Abstract

Background/Objectives: Edentulism is a prevalent chronic condition among older adults, and conventional complete dentures remain the standard of care. However, their fabrication often involves multiple clinical sessions and operator-dependent steps that may compromise fit and comfort. Digital workflows using CAD/CAM technologies have emerged as viable alternatives, offering improved efficiency, precision, and patient-centered outcomes. This case report aims to present a fully digital workflow for maxillary complete dentures and describe clinical efficiency and patient-reported outcomes. Case Presentation: A 73-year-old edentulous male patient underwent maxillary rehabilitation using a fully digital workflow. The protocol included intraoral scanning; the design and 3D printing of a custom tray with occlusal rims; border-molded functional impressions; virtual articulation; and CAD/CAM fabrication. A digitally designed Try-In denture was 3D printed for clinical evaluation, followed by adjustments. The definitive prosthesis was milled from high-performance PMMA discs using a five-axis milling machine. The workflow reduced the number of appointments and laboratory steps. At six-month follow-up, the patient reported high satisfaction with esthetics, retention, phonetics, and masticatory performance. No significant post-delivery adjustments were required. Conclusions: This case demonstrates that fully digital workflows for maxillary complete dentures are clinically viable, providing excellent precision, patient satisfaction, and time efficiency compared to conventional methods. The reproducible protocol described may support the broader integration of CAD/CAM technologies in edentulous rehabilitation.