Three dimensional analysis on the deformation of the master cast during maxillary complete denture fabrication

This study aimed to assess the changes in maxillary master casts that occur during complete denture fabrication, focusing on a compression molded denture. Digital merging techniques were used to measure the changes in 12 maxillary master casts at various fabrication stages. Measurements were performed from master cast formation to teeth arrangement using scanable ball markers and digital overlay techniques. The changes observed in the master cast were categorized as follows: S12 for the alterations from cast fabrication to occlusal rim formation, S23 for the alterations from recording jaw relations to teeth arrangement, and S13 for the overall changes throughout the entire fabrication process. The posterior seal area exhibited the most significant changes, until the jaw relation stage (S12). Statistical analyses revealed significant differences in changes among anatomical areas at different fabrication stages. These findings underscore the importance of considering alterations in the master cast during denture fabrication, when using traditional methods. Traditional techniques, such as the flask-pack-press, can induce substantial alterations in areas critical for denture retention and stability. This study highlights the need for a comprehensive assessment of fabrication processes to enhance denture quality and patient satisfaction. It provides valuable insights into master cast alterations that occur during complete denture fabrication. Efforts to minimize deformations in master casts are essential for improving patient satisfaction and oral health outcomes.