Digital workflow for a 3D-Printed speech bulb denture in an edentulous Post-Oncologic patient with velopharyngeal...

Velopharyngeal insufficiency (VPI) following oncologic resection of the soft palate in edentulous patients presents a major clinical challenge, often leading to hypernasal speech, nasal regurgitation, and impaired swallowing. Advances in digital technology have enabled the fabrication of precise and functionally efficient prostheses through computer-aided design/computer-aided manufacturing (CAD/CAM) and three-dimensional (3D) printing.

This report describes the prosthodontic rehabilitation of a 68-year-old male with post-radiotherapy soft palate resection using a fully digital workflow to fabricate a 3D-printed complete denture with an integrated speech bulb. Following a conventional preliminary impression, the definitive cast was digitised, and all subsequent stages --including custom tray design, virtual denture base modelling, and prosthesis fabrication --were performed using CAD software and additive manufacturing. The speech bulb extension was digitally contoured to achieve functional velopharyngeal closure. At insertion and during the three-month follow-up, the prosthesis demonstrated excellent adaptation, retention, and comfort, with significant improvement in speech intelligibility, swallowing, and overall quality of life.

This case highlights the clinical advantages of integrating digital workflows and 3D printing in maxillofacial prosthetic rehabilitation, providing a reproducible, minimally invasive, and patient-centred approach for managing velopharyngeal insufficiency following oncologic resection.