PEEK Maxillary Obturator Prosthesis Fabrication Using Intraoral Scanning, 3D Printing, and CAD/CAM

This report presents a digital technique for the fabrication of a two-piece hollow bulb maxillary obturator prosthesis. The procedure described resulted in an accurate prosthesis while avoiding the discomfort associated with analog impressions. The manipulation of a routine postoperative CT scan in conjunction with a 3D printer allowed for the fabrication of a 3D-printed anatomical cast, from which the two-piece hollow bulb obturator was fabricated. The obturator prosthesis framework was digitally designed and milled from a modified PEEK material, resulting in a lightweight prosthesis with excellent biocompatibility. The clinical and laboratory steps involved are described.